2001 Berlingo
Uploaded by
Mr.Ponkasem Ponraksa2001 Berlingo
Uploaded by
Mr.Ponkasem PonraksaPRIVATE CARS
2001
SAXO-XSARA-BERLINGO
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the
motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The
information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full
responsibility to the exclusion of that of the manufacturer».
’’The technical information appearing in this brochure is subject to updating as the characteristics of each
model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically
for further information and to obtain any possible updates».
CAR 050008
Book 1
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PRESENTATION
THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including COMMERCIAL
vehicles for which there exists a separate handbook.
The handbook is divided into nine groups representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL -
AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order : SAXO - XSARA – XSARA PICASSO - BERLINGO and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
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IMPORTANT
If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account
when preparing future publications. For example :
– INSUFFICIENT INFORMATION
– SUPERFLUOUS INFORMATION
– NEED FOR MORE DETAILS
Please send your comments and suggestions to :
CITROEN U.K. Ltd.
221, Bath Road,
SLOUGH,
SL1 4BA.
U.K.
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INDEX
GENERAL LPG safety requirements 166 - 170 Handbrake 302
Saxo
Saxo 1-8 HDi safety requirements 171 - 174 Bleed brakes 303
Xsara 9/2000 9 - 24 Checking the HDi fuel circuit 175 - 176 Handbrake 319
Identification Xsara
Xsara 09/2000 25 - 31 Checking the HDi air circuit 177
Bleed brakes 302
of vehicles Xsara Picasso 32 - 33 Checking turbo pressure 178 - 179
Checking the HDi recycling circuit 180 Xsara Handbrake 330
Berlingo 34 - 37 Picasso
Checking, setting DELPHI injection 181 - 195 Bleed brakes 331
Saxo 39
Xsara 9/2000 40 Checking, setting BOSCH injection 196 - 205 ELECTRICAL
Capacities Xsara 09/2000 41 IGNITION Starters 332 - 340
Xsara Picasso 42 Sparking plugs 206 Alternators 341 - 354
Berlingo 43
CLUTCH-GEARBOX-TRANSMISSION Charging circuit 355
Lubricants 44 - 58
Speedometer 207 Preheater plugs 356 - 357
ENGINE
Checking, adjusting the clutch 211 - 216 AIR CONDITIONING
Specifications 59 - 62
Driveshafts 250
Cylinder head marking, tightening 66 - 77 Quantity in R 134.a 358
Auxiliary drive belt 78 - 102 AXLES-SUSPENSION-STEERING
Special features 359 - 366
Checking, setting valve timing 103 - 104 Saxo 251 - 258
Axle geometry Checking temperatures 367 - 368
Valve clearances 140 Xsara TT 263 - 267
Xsara Picasso 292 - 293 Checking pressures 369 - 370
Checking oil pressure 141
Oil filter 144 Saxo 371 - 374
BRAKES
INJECTION Saxo 298 - 299 Air conditioning Xsara 09/2000 375 - 381
Brake circuit Xsara 09/2000 382 - 385
Idling, anti-pollution 146 - 149 specifications Xsara 304 - 306
Petrol injection 150 - 157 Xsara Picasso 321 Xsara Picasso 386 - 390
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IDENTIFICATION OF VEHICLES SAXO - All Types
1 Engine legislation type
2 RP organisation no.
3 Chassis stamp
GENERAL
4 Manufacturer's name plate
5 01/02/99 # Label :
- Tyre pressures.
- RP organisation no.
- Paint code.
6 Paint code.
7 Gearbox ident. reference
E1AP07CD
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SAXO - All Types IDENTIFICATION OF VEHICLES
3-DOOR PETROL SALOONS
1.0 i 1.1 i 1.4 i
AUTO.
A-X SX SX
Administration A-X Exclusive VTS VTS
Emission standard L3 IF/L4
GENERAL
Type code SO CDZF SO HDZF/GL (1) SO KFXD S6 KFXB/IF SO KFXB/IF
Engine type CDZ HDZ KFX
Cubic capacity (cc) 954 1124 1360
Fiscal rating (hp) 4 6 5
Gearbox type MA/5 MB3 MA/5
20 CE 81 (2) 20 CE 95 (2) 20 CE73 (2)
Gearbox ident. plate
20 CF 03 (3) 312 20 CF 12 (3) 20 CF 02 (3)
(1) = LPG.
(2) = # 28/08/2000.
(3) = 29/08/2000 #
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IDENTIFICATION OF VEHICLES SAXO - All Types
3-DOOR PETROL SALOONS 3-DOOR DIESEL SALOONS
1.6 i 1.6 i 16 V 1.5 D
A-X-SX
Exclusive
VTS VTS Administration S - SX
Emission standard L3
Type code S6 NFZF S6 NFXF SO VJZF SO VJYF
GENERAL
Engine type NFZ NFX VJZ (1) VJY (2)
Cubic capacity (cc) 1587 1527
Fiscal rating (hp) 6 8 4
Gearbox type MA/5
20 CD 60 (3) 20 CD 46 (3) 20 CE 73 (3)
Gearbox ident. plate
20 CN 05 (4) 20 CN 03 (4) 20 CF 02 (4)
(1) = With EGR
(2) = Catalytic converter with EGR
(3) = # 28/08/2000.
(4) = 29/08/2000 #
NOTE : EGR = Exhaust Gas Recycling device.
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SAXO - All Types IDENTIFICATION OF VEHICLES
5-DOOR PETROL SALOONS
1.0 i 1.1 i 1.4 i
AUTO.
(1) (2)
A-X A-SX
Administration Driving School SX - Exclusive SX
Emission standard L3 IF/L4
GENERAL
Type code S1 CDZF S1 HDZF/GL (3) S1 KFXD S1 KFXB/IF
Engine type CDZ HDZ KFX
Cubic capacity (cc) 954 1124 1360
Fiscal rating (hp) 4 6 5
Gearbox type MA/5 MB3 MA/5
20 CE 81 (4) 20 CE 73 (4)
Gearbox ident. plate 312
20 CF 03 (5) 20 CF 02 (5)
(1) = Cylindrical tank
(2) = Ring-shaped tank.
(3) = LPG.
(4) = # 28/08/2000
(5) = 29/08/2000 #
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IDENTIFICATION OF VEHICLES SAXO - All Types
5-DOOR DIESEL SALOONS
1.5 D
A-X-SX-Exclusive
A-X-SX-Exclusive Driving School
Administration
Emission standard L3
Type code S1 VJZF (1) S1 VJZF/MOD (2) S1 VJYF (3)
GENERAL
Engine type VJZ VJY
Cubic capacity (cc) 1527
Fiscal rating (hp) 4
Gearbox type MA/5
Gearbox ident. plate 20 CE 73 (a) 20 CF 02 (b)
(1) = With EGR
(2) MOD = Modifiable.
(3) = Catalytic converter
(a) = # 28/08/2000.
(b) =.29/08/2000 #
NOTE : EGR = Exhaust Gas Recycling device.
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SAXO - All Types IDENTIFICATION OF VEHICLES
Commercial version Entreprise 3 door
Petrol Diesel
1.0 i 1.1 i 1.5D
A-X-Poste A-X-Poste
Administration A Administration
Emission standard L3
Type code SO CDZF/T (1) S3 CDZF (2) SO HDZF SO VJZF/T (1) S3 VJZF (2)
GENERAL
/T.MOD.GL (3)
Engine type CDZ HDZ VJZ
Cubic capacity (cc) 954 1124 1527
Fiscal rating (hp) 5 6 6
Gearbox type MA/5
20 CE 81 (4) 20 CE 73 (4)
Gearbox ident. plate
20 CF 03 (5) 20 CF 02 (5)
(1) = Can be converted.
(2) = Non-convertible van.
(3) /T.MOD.GL = Convertible to LPG.
(4) = # 28/08/2000.
(5) = 29/08/2000 #
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IDENTIFICATION OF VEHICLES SAXO - All Types
3-DOOR SALOONS
Petrol Diesel
1.1i 1.4i 1.6i 1.6i 16V 1.5 D
A-X-SX A-X-SX
Exclusive VTS SX – Exclusive Exclusive
Administration VTS VTS VTS Administration
Emission standard L4
GENERAL
Type code SO HFXB S6 KFWB SO KFWB S6 NFTB S6 NFXB SO VJXB
Engine type HFX KFW NFT NFX VJX
Cubic capacity (cc) 1124 1360 1587 1527
Fiscal rating (hp) 4 5 6 8 4
Gearbox type MA/5
20 CF 03 (1) 20 CE 95 (1) 20 CD 46 (1) 20 CE 73 (1)
Gearbox ident. plate 20 CF 03
20 CF 02 (2) 20 CF 12 (2) 20 CN 03 (2) 20 CF 02 (2)
(1) = # 02/05/2000
(2) = 03/05/2000 #
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SAXO - All Types IDENTIFICATION OF VEHICLES
COMMERCIAL VERSION ENTREPRISE 3 DOOR
Petrol Diesel
1.1i 1.5 D
(1) (1)
A-S-SX A-S-SX
Poste Poste
Administration Administration
GENERAL
Emission standard L4 L4
Type code S3 HFXB S3 VJXB
Engine type HFX VJX
Cubic capacity (cc) 1124 1527
Fiscal rating (hp) 6 6
Gearbox type MA/5 MA/5
20 CE 81 (1) 20 CE 73 (1)
Gearbox ident. plate
20 CF 03 (2) 20 CF 02 (2)
(1) = Non-convertible van
(2) = # 28/08/2000
(3) = 29/08/2000 #
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
1 Manufacturer’s name plate (Estate).
2 Chassis stamp
3 Manufacturer’s name plate (Saloon)..
GENERAL
4 01/02/1999 # Label :
- Tyre pressures.
- RP organisation no.
- Paint code.
5 Gearbox ident. reference
6 Engine legislation type
E1AP08MD
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
3-DOOR PETROL SALOONS
1.4i 1.6i
Dual fuel AUTO.
A - X - X Pack X - X Pack X - X Pack X - X Pack
X - X Pack SX - VTR SX X - SX SX - VTR SX - Exclusive
Emission standard K' L3 IF L4 L3
GENERAL
Type code NO KFXG NO KFXF NO KFXB NO KXF/GL (1) NO NFZF NO NFZM
Engine type KFX NFZ
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 6
Gearbox type MA/5 MA/5 AL4
Gearbox ident. plate 20 CE 42 (*) 20 CD 29 20 TP 22
(*) = Differential diameter 68 mm.
(1) GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.
10
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
3-DOOR PETROL SALOONS
1.8i 1.8i 16V 2.0i 16V
X - X Pack X Pack - SX
SX - VTR Exclusive VTR - VTS VTS Brazil
Emission standard L3
GENERAL
Type code NO LFXF NO LFYF N6 LFYF N6 RFSF N6 RFSY
Engine type LFX LFY RFS
Cubic capacity (cc) 1761 1998
Fiscal rating (hp) 6 7 11
Gearbox type BE3/5
Gearbox ident. plate 20 TB 91 20 TB 62 20 TB 92 20 TB 93
11
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
3-DOOR DIESEL SALOONS
1.9 D 1.9 TD 2.0 HDi (1)
X - X Pack
X - X Pack SX - VTR X - X Pack X - X Pack
VTR Exclusive VTS SX VTR - VTS SX VTR - VTS
GENERAL
Emission standard L3 L4
Type code NO WJZF NO DHYF N6 DHYF NO RHYF N6 RHYF NO RHYB N6 RHYB
Engine type WJZ DHY RHY
Cubic capacity (cc) 1868 1905 1997
Fiscal rating (hp) 5 6 5
Gearbox type BE3/5
Gearbox ident. plate 20 TB 38 20 TB 59 20 TB 51
(1) = High pressure Diesel injection
12
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
3-DOOR SALOON VERSIONS - ALL TYPES
Petrol Diesel
1.4i 1.9 D
Dual fuel
X Entreprise
X Entreprise SX X Entreprise
L3
GENERAL
Emission standard
Type code NO KFXF/T (1) NO KFXF/T MOD GL (2) NO WJZF/T (1) N3 WJZF
Engine type KFX WJZ
Cubic capacity (cc) 1360 1868
Fiscal rating (hp) 5
Gearbox type MA/5
Gearbox ident. plate 20 CE 42 20 TB 38
(1) /T = The vehicle can be converted back into a private vehicle.
(2) /T MOD GL :
/T = The vehicle can be converted back into a private vehicle.
MOD = Modifiable.
GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.
13
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
5-DOOR PETROL SALOONS
1.4 i 1.6i
Dual fuel AUTO.
A-X
A-X X Pack - SX X - X Pack
X Pack Exclusive SX X-SX X Pack
Emission standard K' L3 L4 L3 K'
GENERAL
Type code N1 KFXG N1 KFXF N1 KFXB N1 KFXF/GL (1) N1 NFZG N1 NFZU
Engine type KFX NFZ
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 6
Gearbox type MA/5 MA/5 AL4
Gearbox ident. plate 20 CE 42 (1) 20 CE 29 20 TP 22
(1) = Differential diameter 68 mm.
14
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
5-DOOR PETROL SALOONS
1.6i 1.8i 1.8i 16V
AUTO.
X - X Pack - SX X - X Pack - SX X - X pack - SX
Exclusive Exclusive Exclusive VTS
Emission standard L3
GENERAL
Type code N1 NFZF N1 NFZM N1 LFXF N1 LFYF N7 LFYF
Engine type NFZ LFX LFY
Cubic capacity (cc) 1587 1761
Fiscal rating (hp) 6 7
Gearbox type MA/5 AL4 BE3/5
Gearbox ident. plate 20 CD 29 20 TP 22 20 TB 91 20 TB 84
15
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
5-DOOR PETROL SALOONS
1.8i 16V 2.0i 16V
Dual fuel AUTO.
X - X Pack
Brazil X - SX Exclusive Brazil
Emission standard L3
GENERAL
Type code N1 LFYY N1 LFYF/GL (1) N1 RFVF N1 RFVB N1 RFVY
Engine type LFY RFV
Cubic capacity (cc) 1761 1998
Fiscal rating (hp) 7 9
Gearbox type BE3/5 BE3/5 4HP20 BE3/5
Gearbox ident. plate 20 TD 05 20 TB 84 20 TB 39 20 GZ 9F 20 TB 39
(1) GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.
16
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
5-DOOR DIESEL SALOONS
1.5 D 1.9D 2.0 HDi
X - X Pack X - X Pack - SX
SX SX Exclusive
Emission standard L3 L4
GENERAL
Type code N1 VJZF N1 WJZF N1 RHYF N1 RHYB
Engine type VJZ WJZ RHY
Cubic capacity (cc) 1527 1868 1997
Fiscal rating (hp) 4 5 5
Gearbox type MA/5 BE3/5
Gearbox ident. plate 20 CE 46 (*) 20 TB 38 20 TB 51
(*) = Differential diameter 68 mm.
17
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
5-DOOR SALOON VERSIONS – ALL TYPES
Petrol Diesel
1.4i 1.8i 1.9 D
X Police Unmarked X Police Marked
X Police Marked X Police Marked X Gendarmerie X Administration
Emission standard L3
GENERAL
Type code N1 KFXF N1 LFXF N1 WJZF N1 WJZC
Engine type KFX LFX WJZ
Cubic capacity (cc) 1360 1761 1868
Fiscal rating (hp) 5 6 5
Gearbox type MA/5 BE3/5 BE3/5
Gearbox ident. plate 20 CE 42 20 TB 22 20 TB 38
(1) /T = The vehicle can be converted back into a private vehicle.
(2) /T MOD GL :
/T = The vehicle can be converted back into a private vehicle
MOD = Modifiable.
GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.
18
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
5-DOOR SALOON VERSIONS
Diesel
1.9 D 1.9 TD 2.0 HDi
X Driving School X Entreprise X Entreprise X Police Spain X Entreprise
Emission standard L3 W3
GENERAL
Type code N1 WJZF/MOD (1) N1 WJZF/T (2) N1 DHYF N1 RHYF N1 RHYF/T (2)
Engine type WJZ DHY RHY
Cubic capacity (cc) 1868 1905 1997
Fiscal rating (hp) 5 6 5
Gearbox type BE3/5
Gearbox ident. plate 20 TB 38 20 TB 59 20 TB 51 20 TB 38
(1) /T = The vehicle can be converted back into a private vehicle.
(2) MOD = Modifiable.
19
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
PETROL ESTATES
1.4i 1.6i
Dual fuel AUTO. AUTO.
(1)
X - X Pack - SX X - SX X Pack X - X - Pack SX - Exclusive
GENERAL
Emission standard L3 L4 L3
Type code N2 KFXF N2 KFXB N2 KFXF/GL N2 NFZU N2 NFZG N2 NFZF N2 NFZM
Engine type KFX NFZ
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 6
Gearbox type MA/5 AL4 MA/5 AL4
Gearbox ident. plate 20 CD 28 (*) 20 TP 22 20 CD 30 20 TP 22
(1) /GL = LPG (Liquid Petroleum Gas).
(*) = Differential diameter 77 mm.
20
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
PETROL ESTATES
1.8i 1.8i 16V 2.0i 16V
Dual fuel AUTO.
X – X Pack – SX X – X Pack – SX (1)
Exclusive Exclusive X – SX Brazil X – X Pack – SX – Exclusive
Emission standard L3
GENERAL
Type code N2 LFXF N2 LFYF N2 LFYF/GL N2 LFYY N2 RFVF N2 RFVM
Engine type LFX LFY RFV
Cubic capacity (cc) 1761 1761 1998
Fiscal rating (hp) 6 7 9
Gearbox type BE3/5 BE3/5 BE3/5 4HP14
Gearbox ident. plate 20 TB 22 20 TB 62 20 TD 05 20 TB 39 20 GZ 9F
(1) GL = LPG (Liquid Petroleum Gas).
21
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
DIESEL ESTATES
1.5 D 1.9 D 1.9 TD 2.0 HDi
X – X Pack
X – X Pack SX
SX SX Exclusive X – X Pack – SX - Exclusive
Emission standard L3 L4
Type code N2 VJZF N2 WJZF N2 DHYF N2 RHYF N2 RHYM
GENERAL
Engine type VJZ WJZ DHY RHY
Cubic capacity (cc) 1527 1868 1905 1997
Fiscal rating (hp) 4 5 6 5
Gearbox type MA/5 BE3/5 BE3/5
Gearbox ident. plate 20 CD 33 (*) 20 TB 38 20 TB 59 20 TP22
(*) = Differential diameter 68 mm.
22
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
ESTATE VERSIONS
Petrol
1.4i 1.6i
Dual fuel
X Police Unmarked
X Police Marked X Entreprise X – SX Entreprise X Police Unmarked
Emission standard L3
GENERAL
Type code N2 KFXF N2 KFXF/T (1) N2 KFXF/T MOD GL (2) N2 LFXF
Engine type KFX LFX
Cubic capacity (cc) 1360 1761
Fiscal rating (hp) 6 5 6
Gearbox type MA/5 BE3/5
Gearbox ident. plate 20 CD 28 20 TB 22
(1) /T = The vehicle can be converted back into a private vehicle.
(2) /T MOD GL :
/T = The vehicle can be converted back into a private vehicle
MOD = Modifiable.
GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.
23
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XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES
ESTATE VERSIONS
Diesel
1.9 D
X Police Unmarked
X Police Marked X Entreprise
Emission standard L3
GENERAL
Type code N2 WJZF WJZF/T (1) N2 WJZF
Engine type WJZ
Cubic capacity (cc) 1868
Fiscal rating (hp) 5
Gearbox type BE3/5
Gearbox ident. plate 20 TP 38
(1) = Can be converted.
24
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IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000
09/2000 # A - Manufacturer’s name plate (Estate).
B - Chassis stamp, cold stamp.
C - Manufacturer’s name plate (Saloon).
D - Label :
(affixed on windscreen pillar on driver’s side)
GENERAL
- Tyre pressures.
- RP organisation no.
- Paint code.
E - Serial No. (visible through the windscreen)
F - Engine legislation type.
Factory Serial No.
G - Gearbox ident. reference.
Factory Serial No
E1AP08WD
25
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XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES
3-DOOR PETROL SALOONS
1.4 i 1.6i 16V 2.0i 16V
AUTO. AUTO.
X-SX X-SX-VTR
VTR VTS SX-VTR VTS VTS
Emission standard L4 IFL5 L4
GENERAL
Type code NO KFWB NO NFUB NO NFUN NO RFN1/IF NO RFN3/IF NO RFSB
Engine type KFW NFU RFN RFS
Cubic capacity (cc) 1360 1587 1998
Fiscal rating (hp) 5 7 8 11
Gearbox type MA/5 AL4 AL4 BE4/5 BE4/5
Gearbox ident. plate 20 CF 13 (1) 20 CN 28 (2) 20 TP 49 20TP47 20 TE 40 (3) 20 TE 47
(1) = Grand Export 20 CN 30
(2) = Grand Export 20 CN 29
(3) = Right Hand Drive 20 DM 03
26
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IDENTIFICATION OF VEHICLES XSARA - All Types 09/2000 #
3-DOOR PETROL SALOONS PETROL / DIESEL VERSIONS
1.9 D 2.0 HDi 1.4i 1.9 D 2.0 HDi
X-SX X-SX-VTR
VTR VTS Entreprise
Emission standard L4 L4
Type code NO WJZB NO RHYB NO KFWB/T (1) NO WJZB/T (1) NO RHYB/T (1)
GENERAL
Engine type WJZ RHY KFW WJZ RHY
Cubic capacity (cc) 1868 1997 1360 1868 1997
Fiscal rating (hp) 5 5
Gearbox type BE4/5 MA/5 BE4/5
Gearbox ident. plate 20 DL (2)-(3) 20 DL (4)-(5) 20 CF 13 (6) 20 DL (2)-(3) 20 DL (4)-(5)
(1) /T = The vehicle can be converted back into a private vehicle
(2) = Left Hand Drive version 20 DL 41
(3) = Right Hand Drive version 20 DM 05
(4) = Left Hand Drive version 20 DL 42
(5) = Right Hand Drive version 20 DM 07
(6) = Grand Export 20 CN 30
27
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XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES
5-DOOR PETROL SALOONS
1.4 i 1.6i 16V
AUTO. AUTO.
X-SX SX
X X-SX SX Exclusive Exclusive
GENERAL
Emission standard K’ L4 K’ L4
Type code N1 KFWG N1 KFWB N1 NFUG N1 NFUU N1 NFUB N1 NFUN
Engine type KFW NFU
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 7
Gearbox type MA/5 AL4 MA/5 AL4
Gearbox ident. plate 20 CF 21 20 CN 28 (1) 20 TP 49 20 CN 28 (1) 20 TP 49
(1) = Grand Export 20 CN 29
28
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IDENTIFICATION OF VEHICLES XSARA - All Types 09/2000 #
5-DOOR PETROL SALOONS 5-DOOR DIESEL SALOONS
2.0i 16V 1.9 D 2.0 HDi
AUTO.
Exclusive X-SX
Emission standard IFL5 L4
GENERAL
Type code N1 RFN1/IF N1 RFN3/IF N1 WJZB N1 RHYB
Engine type RFN WJZ RHY
Cubic capacity (cc) 1998 1868 1997
Fiscal rating (hp) 11 5
Gearbox type BE4/5 AL4 BE4/5
Gearbox ident. plate 20 DL (1) (2) 20 TP 47 20 DL (3)-(4) 20 DL (5)-(6)
(1) = Left Hand Drive version 20 DL 40 (5) = Left Hand Drive version 20 DL 42
(2) = Right Hand Drive version 20 DM 03 (6) = Right Hand Drive version 20 DM 07
(3) = Left Hand Drive version 20 DL 41
(4) = Right Hand Drive version 20 DM 05
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XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES
PETROL SALOONS / ESTATES
1.4 i 1.6i 16V 2.0i 16V
AUTO. AUTO.
SX
X-SX SX X-SX Exclusive Exclusive
GENERAL
Emission standard L4 K' L4 IFL5
Type code N2 KFWB N2 NFUG N2 NFUB N2 NFUN N2 RFN1/IF N2 RFN3/IF
Engine type KFW NFU RFN
Cubic capacity (cc) 1360 1587 1998
Fiscal rating (hp) 5 7 11 11
Gearbox type MA/5 AL4 BE4/5 AL4
Gearbox ident. plate 20 CN 21 20 CN 29 (1) 20 CN 28 20 TP 47 20 DL (2)-(3) 20 TP 47
(1) = Grand Export 20 CN 29
(2) = Left Hand Drive version 20 DL 40
(3) = Right Hand Drive version 20 DM 03
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IDENTIFICATION OF VEHICLES XSARA - All Types 09/2000 #
DIESEL ESTATES PETROL / DIESEL ESTATE VERSIONS
1.9 D 2.0 HDi 1.4i 1.9 D 2.0 HDi
X-SX
X-SX Exclusive Entreprise Entreprise
Emission standard L4
Type code N2 WJZB N2 RHYB N2 KFWB/T (1) N2 WJZB/T (1) N2 RHYB/T (1)
GENERAL
Engine type WJZ RHY KFW WJZ RHY
Cubic capacity (cc) 1868 1997 1360 1868 1997
Fiscal rating (hp) 5 5
Gearbox type BE4/5 MA/5 BE4/5
Gearbox ident. plate 20 DL (2)-(3) 20 DL (4)-(5) 20 CN 21 (6) 20 DL (2)-(3) 20 DL (4)-(5)
(1) /T = The vehicle can be converted back into a private vehicle
(2) = Left Hand Drive version 20 DL 41
(3) = Right Hand Drive version 20 DM 05
(4) = Left Hand Drive version 20 DL 42
(5) = Right Hand Drive version 20 DM 07
(6) = Grand Export 20 CN 30
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XSARA PICASSO - All Types IDENTIFICATION OF VEHICLES
A - Chassis stamp
(Cold stamp on bodywork)
B - Chassis no. reminder
(Label located at bottom of windscreen right hand side)
C - Manufacturer’s data plate.
(Located at bottom of RH central pillar).
D - Label :
GENERAL
Tyre pressures.
Tyre identification.
Spare wheel identification.
(Located on front LH door inner panel).
E - Label :
Factory code.
A-S / RP N°.
Paint code.
(Located on fuse box cover).
F - Gearbox identification ref.
G - Engine legislation type.
Factory serial number.
E1AP088D
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IDENTIFICATION OF VEHICLES XSARA PICASSO - All Types
Petrol Diesel
1.6i 1.8i 16 V 2.0 HDi
Emission standard L3 L3 ou L4
Type code CH NFZ CH 6FZ CH RHY
GENERAL
Engine type NFZ 6FZ RHY
Cubic capacity (cc) 587 1749 1997
Fiscal rating (hp) 6 7 5
Gearbox type BE4/5/ J (*) BE4/5 V (*) BE4/5 L (*)
Gearbox ident. plate 20 DL 66 20 DL 68 20 DL64
(*) L,J, V = Corresponds to the stepping of the gears.
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BERLINGO - All Types IDENTIFICATION OF VEHICLES
1 Chassis stamp
2 Manufacturer’s name plate
3 Supplementary plate
4 Weights label
GENERAL
5 01/02/99 # Label :
- Tyre pressures.
- RP organisation no.
- Paint code.
6 Paint code
7 RP organisation no.
8 Gearbox ident. reference
9 Engine legislation type
E1AP07AD
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IDENTIFICATION OF VEHICLES BERLINGO - All Types
PETROL
1.1i 1.4i
X X X-SX Multispace X-SX
Emission standard L3/W3 L4/W4 K' L3/W3 L4/W4
GENERAL
Type code MF HDZF MF HFXB MF KFXG MF KFXF MF KFXF/A MF KFWB
Engine type HDZ HFX KFX KFW
Cubic capacity (cc) 1124 1360
Fiscal rating (hp) 5 6
Gearbox type MA/5
20 CN 43 # 09/200
Gearbox ident. plate 20 CN 12 20 CN 13 20 CN 12
20 CN 02 09/2000 #
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BERLINGO - All Types IDENTIFICATION OF VEHICLES
PETROL
1.4i 1.8i
Dual fuel
X Multispace SX Multispace
Multispace
Emission standard L4/W4 L3 L3/W3
GENERAL
MF KFXF MF KFXF
Type code MF KFWB/A /MOD GL /MOD GL MF LFXF MF LFXF/A
Engine type KFW KFX LFX
Cubic capacity (cc) 1360 1761
Fiscal rating (hp) 6 7
Gearbox type MA/5 BE3/5
Gearbox ident. plate 20 CN 13 20 CN 12 20 CN 13 20 TE 25 20 TE 26
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IDENTIFICATION OF VEHICLES BERLINGO - All Types
DIESEL
1.9 D 2.0 HDi
X-SX Multispace X-SX Multispace Multispace Multispace
Emission standard L3/W3 L4/W4 L3/W3 L4/W4
GENERAL
Type code MF WJZF MF WJZF MF WJYB MF WJYB MF RHYF MF RHYF MF RHYB MF RHYB
/A /A /A /A
Engine type WJZ WJY RHY
Cubic capacity (cc) 1868 1997
Fiscal rating (hp) 5 6
Gearbox type BE3/5
Gearbox ident. plate 20 TE 22 20 TE 24 20 TE 49 20 TE 24 20 TE 28 20 TE 29 20 TE 28 20 TE 29
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ALL TYPES CAPACITIES (in litres)
Draining method.
The oil capacities are defined according to the following methods.
1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension).
2/ Engine warm (oil temperature 80°C).
GENERAL
3/ Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min).
4/ Refit plug + cartridge.
5/ Engine filling.
6/ Engine starting (allowing the cartridge to be filled).
7/ Engine stopped (stationary for 5 min).
ESSENTIAL : Systematically check the oil level using the oil dipstick.
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CAPACITIES (in litres) SAXO - All Types
SAXO
Petrol Diesel
Ecological oil filter
capacity 0.15 litre.
1.0I 1.1I 1.4I 1.6I 1.1I 1.4I 1.6I 1.6I 1.6I 1.6I 1.5D
16V
AUTO.
GENERAL
Engine type CDZ HDZ KFX KFW NFZ NFX KFX KFW NFZ NFX NFT VJZ VJY VJX
Engine with filter change 3 3 3.5 4.5
Between Min. and Max. 1.4 1.5 1.5 2
5-speed gearbox 2 2
Automatic gearbox 4.5
after drainage 2
Hydraulic or brake circuit With ABS : 0.45 - Without ABS : 0.36
Cooling system 6.1
Fuel tank capacity 45
ESSENTIAL : Engine : systematically check the oil level using the oil dipstick.
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XSARA - All Types # 09/2000 CAPACITIES (in litres)
XSARA # 09/2000
Petrol Diesel
1.8i 2.0i
1.4i 1.6i 1.8i 1.5D 1.9D 1.9TD 2.0HDi
16V 16 V
AUTO. AUTO.
Engine type KFX NFZ LFX LFY RFV RFS VJZ WJZ DHY RHY
GENERAL
4.75 4.75 4 4.5
Engine with filter change 3 4.25 4.5
4.25 (1) 4.5 (1) 4.25 (1) 4.25 (1)
Between Min. and Max. 1.4 1.3 1 2 1.5
5-speed gearbox 2 1.8 1.9 1.9 2 1.8
Automatic gearbox 6 6
after drainage 3 3
Hydraulic or brake circuit With ABS = 0.50 - Without ABS = 0.55
Cooling system 7 - 6.5 (1) 7 9 8.8 9 9 - 9.5 (1) 8.5 - 11 (1)
Fuel tank capacity 54
(1) With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dipstick.
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CAPACITIES (in litres) XSARA - All Types 09/2000 #
XSARA 09/2000 #
Petrol Diesel
Ecological oil filter
capacity 0,15 litre.
1.4 i 1.6 i 16V 2.0i 16V 1.9D 2.0 HDi
AUTO. AUTO.
Engine type KFW NFU RFN RFS WJZ RHY
GENERAL
Engine with filter change 3 3.25 4.25 4.75 4.5
Between Min. and Max. 1.5 1.5 1.7 1 1.6 1.4
5-speed gearbox 2 1.9 1.9 1.8
Automatic gearbox 6 6
after drainage 3 3
Hydraulic or brake circuit With ABS = 0.50 - Without ABS = 0.55
Cooling system 7 - 6.5 (1) 9 8.5 - 11 (1)
Fuel tank capacity 54
(1) = With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dipstick.
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XSARA PICASSO - All Types CAPACITIES (in litres)
XSARA PICASSO
Petrol Diesel
Cartouche écologique
capacité 0.15 Litre.
1.6I 1.8I 16 V 2.0 HDI
Engine type NFZ 6FZ RHY
Engine with filter change 3 4.25 4.5
GENERAL
Between Min. and Max. 1.5 1.7 1.4
5-speed gearbox 1.8
Automatic gearbox
after drainage
Hydraulic or brake circuit 0.58 litres
Cooling system 5.8 (1) and (2) 6.5 (1) and (2) 11 (1) and (2)
Fuel tank capacity 55 60
(1) = With aircon
(2) = Without aircon
ESSENTIAL : Engine : systematically check the oil level using the oil dipstick.
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CAPACITIES (in litres) BERLINGO - All Types
BERLINGO
Petrol Diesel
Ecological oil filter
capacity 0,15 litre.
1.1I 1.4I 1.8I 1.1I 1.4I 1.9D 2.0 HDI
Engine type HDZ HFX KFX KFW LFX HFX KFX KFW WJZ RHY
GENERAL
4.75 4.75 4.5
Engine with filter change 3.5 3
4.5 (1) 4.5 (1) 4.25 (1)
Between Min. and Max. 1.5 1.3 1.5 1.5
5-speed gearbox 2 1.8 2 1.8
Automatic gearbox
after drainage
With ABS = 0.62
Hydraulic or brake circuit With ABS = 0.62 - Without ABS = 0.525
Without ABS = 0.525
Cooling system 6.5 6.5-7 (1) 8 6.5 6.5-7 (1) 10.5
Fuel tank capacity 55 60
(1) = With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dipstick.
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ALL TYPES LUBRICANTS - TOTAL recommended oils
S.A.E. Norm - Table for selection of engine oil grade Factory evolutions in 2000 model year
CITROËN engines are lubricated at the factory with TOTAL oil of
grade S.A.E.5W-30.
TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies
(approx. 2.5%).
This oil is not used in the following engines :
GENERAL
- XU10 4 RS - XSARA VTS 2.0i 16V (3-door)
- SOFIM - RELAY 2.8 D and 2.8 TD.
Engine oil norms
These engine oils have been classified by the following recognised
organisations:
SAE : Society of Automotive Engineers.
API : American Petroleum Institute.
ACEA : Association des Constructeurs Européens
d'Automobiles.
E4AP006D
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LUBRICANTS - TOTAL recommended oils ALL TYPES
Selection of engine oil grades recommended for climatic conditions in countries of distribution
API Norms
ACEA Norms
The first letter corresponds to the type of fuel used by the engine :
The first letter corresponds to the type of engine concerned :
S : petrol and dual fuel petrol / LPG engines.
A : petrol and dual fuel petrol / LPG engines..
C : diesel engines.
B : diesel engines.
GENERAL
The second letter corresponds to the degree of evolution, in ascending order.
The figure following the first letter corresponds to the type of oil.
Example : The norm SJ is more severe than the norm SH and corresponds
1 : highly fluid oils, for reducing friction and lowering fuel consumption.
to a higher level of performance.
3 : high performance oils.
The adding of the letters EC indicates that the engine oil concerned is an
The number after that (96 or 98) corresponds to the year of creation of oil which permits fuel economy.
the norm. EC : Energy Conserving, reduction in fuel consumption.
Examples :
NOTE : From 01/03/2000, all engine oils must comply with ACEA-98 API SJ / CF : Blended oils for diesel and dual fuel petrol / LPG engines
norms. API CF / EC : Oils specifically for diesel engines, permitting fuel economy.
API SJ / CF / EC : Blended oils for all engines, permetting fuel economy.
Example :
ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fuel
economy (complying with ACEA 98 norms).
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ALL TYPES LUBRICANTS - TOTAL recommended oils
Recommendations.
Denominations of TOTAL oils, according to country of marketing :
TOTAL ACTIVA (France only).
TOTAL QUARTZ (outside France).
IMPERATIVE : From 1999 model year, to preserve engine performance, all engines fitted in CITROEN vehicles must be
lubricated with high quality oils (synthetic or semi-synthetic)
These oils must comply with the following norms :
Petrol and dual fuel petrol / LPG engines: ACEA A3-98 and API SJ.
GENERAL
Diesel engines: ACEA B3-98 and API CF.
ATTENTION : Engines fitted in CITROEN vehicles prior to 2000 model year must not be lubricated with oil complying with
standards ACEA A1-98 / B1-98 and API SJ/CF EC.
Summary
Engine oil norms to be respected in 2001 model year.
Model year Types of engine ACEA norms API norms
Petrol and dual fuel petrol /
A3-98 or A1-98 (*) SJ or SJ / EC (*)
2001 model year LPG engines
Diesel engines B3-98 or B1-98 (*) CF or CF / EC (*)
(*) = It is essential not to use engine oils respecting these norms for the following engine-types :
XU10J4RS, 1580 SPI, SOFIM 2.8 D and SOFIM 2.8 TD.
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LUBRICANTS - TOTAL recommended oils ALL TYPES
S.A.E. grades SPI norms ACEA norms
Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel)
TOTAL ACTIVA 9000
5W-40 SJ / CF A3-98 / B3-98
TOTAL QUARTZ 9000
TOTAL ACTIVA 9000 (*)
5W-30 SJ / CF EC A1-98 / B1-98
TOTAL QUARTZ 9000 (*)
TOTAL ACTIVRAC 10W-40 SJ / CF A3-98 / B3-98
(*) = Blended oils for all engines, permitting fuel economy.
GENERAL
Oils specifically for petrol and dual-fuel petrol / LPG engines
TOTAL ACTIVA 7000
10W-40
TOTAL QUARTZ 7000
TOTAL QUARTZ 9000 0W-40 SJ A3-98
TOTAL ACTIVA 7000
15W-50
TOTAL QUARTZ 7000
Oils specifically for diesel engines
TOTAL ACTIVA DIESEL 7000
10W-40
TOTAL QUARTZ DIESEL 7000
TOTAL ACTIVA DIESEL 7000
15W-50 CF B3-98
TOTAL QUARTZ DIESEL 7000
TOTAL ACTIVA 9000 5W-40
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ALL TYPES LUBRICANTS - TOTAL recommended oils
FRANCE
Blended oils for all engines
Metropolitan FRANCE TOTAL ACTIVRAC S.A.E : 10W-40 Norms
TOTAL ACTIVA TOTAL ACTIVA DIESEL
Oils specifically for petrol and Oils specifically
Blended oils for all engines
GENERAL
dual-fuel petrol / LPG engines for diesel engines
900 5W-40 7000 10 W-40 7000 10 W-40
Metropolitan FRANCE
9000 5W-30 (*) 9000 5W-40
New Caledonia
Guadeloupe
Saint-martin
La Réunion
Martinique 9000 5W-40 7000 15W-50 7000 15W-50
Guyana
Tahiti
Mauritius
Mayotte
(*) = Blended oils for all engines, permitting fuel economy.
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LUBRICANTS - TOTAL recommended oils ALL TYPES
EUROPE
TOTAL QUARTZ TOTAL QUARTZ DIESEL
(*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically
permitting fuel economy. Blended oils for all engines
dual-fuel petrol / LPG engines for diesel engines
Germany 7000 10W-40
9000 0W-40
Austria 7000 10W-40 7000 10W-40
GENERAL
7000 10W-40
Belgium
9000 0W-40
Bulgaria 7000 10W-40
7000 10W-40
Cyprus 7000 15W-50
9000 5W-40 7000 15W-50
Croatia 9000 5W-30 (*) 7000 10W-40
7000 10W-40 7000 10W-40
Denmark
9000 0W-40
7000 10W-40 7000 10W-40
Spain
7000 15W-50 7000 15W-50
7000 10W-40
Finland
9000 0W-40 7000 10W-40
Great Britain 7000 10W-40
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ALL TYPES LUBRICANTS - TOTAL recommended oils
EUROPE (continued)
TOTAL QUARTZ TOTAL QUARTZ DIESEL
(*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically
permitting fuel economy. Blended oils for all engines
dual-fuel petrol / LPG engines for diesel engines
7000 10W-40 7000 10W-40
Greece
7000 15W-50 7000 15W-50
Holland 7000 10W-40
GENERAL
Hungary 9000 0W-40
Italy 7000 10W-40
7000 10W-40
Latvia 7000 10W-40
Lithuania 9000 5W-40 9000 0W-40
9000 5W-30 (*)
Macedonia 7000 10W-40
7000 10W-40 7000 10W-40
Malta
7000 15W-50 7000 15W-50
7000 10W-40
Norway
9000 0W-40
Poland
7000 10W-40
Portugal 7000 10W-40
Slovak Republic
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LUBRICANTS - TOTAL recommended oils ALL TYPES
EUROPE (continued)
TOTAL QUARTZ TOTAL QUARTZ DIESEL
(*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically
permitting fuel economy. Blended oils for all engines
dual-fuel petrol / LPG engines for diesel engines
7000 10W-40
Czech Republic 7000 10W-40
9000 0W-40
GENERAL
7000 10W-40 7000 10W-40
Romania
7000 15W-50 7000 15W-50
7000 10W-40
Russia
9000 0W-40
Slovenia 9000 5W-40 7000 10W-40
7000 10W-40
9000 5W-30 (*) 7000 10W-40
Sweden
9000 0W-40
Switzerland 7000 10W-40
7000 10W-40
7000 10W-40
Turkey 7000 15W-50
7000 15W-50
9000 0W-40
7000 10W-40
Ukraine 7000 10W-40
9000 0W-40
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ALL TYPES LUBRICANTS - TOTAL recommended oils
TOTAL QUARTZ TOTAL QUARTZ DIESEL
Blended oils Oils specifically for petrol and Oils specifically
for all engines dual-fuel petrol / LPG engines for diesel engines
Australia
OCEANIA 9000 5W-40 7000 10W-40 7000 10W-40
New Zealand
GENERAL
Angola - Ivory Coast
Egypt- Ecuador - Gabon
Madagascar - Morocco AFRICA 9000 5W-40 7000 15W-50 7000 15W-50
Dominican Republic
Senegal - Tunisia
Argentina - Brazil - Chile
Colombia - Cuba
SOUTH
Guatemala - Paraguay 9000 5W-40 7000 15W-50 7000 15W-50
AMERICA
Peru - El Salvador
Uruguay
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LUBRICANTS - TOTAL recommended oils ALL TYPES
TOTAL QUARTZ TOTAL QUARTZ DIESEL
Blended oils Oils specifically for petrol and Oils specifically
for all engines dual-fuel petrol / LPG engines for diesel engines
7000 10W-40
China 7000 15W-50
GENERAL
South Korea 7000 10W-40
Hong Kong - India
7000 15W-50
Indonesia
7000 10W-40
Japan
SOUTH & EAST 7000 15W-50
9000 5W-40 7000 15W-50
Malaysia ASIA
7000 15W-50
Singapore
Taiwan 7000 10W-40
7000 15W-50
Thaïland
7000 15W-50
Vietnam
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ALL TYPES LUBRICANTS - TOTAL recommended oils
TOTAL QUARTZ TOTAL QUARTZ DIESEL
Blended oils Oils specifically for petrol and Oils specifically
for all engines dual-fuel petrol / LPG engines for diesel engines
Saudi Arabia
GENERAL
Bahrain
Dubaï
United Arab Emirates
Israel MIDDLE
9000 5W-40 7000 15W-50 7000 15W-50
Jordan EAST
Kuwaït
Lebanon
Qatar
Yemen
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LUBRICANTS - TOTAL recommended oils ALL TYPES
Gearbox oils
Europe TOTAL TRANSMISSION
Manual gearbox Overseas France (new formula)
Asia Norms S.A.E 75W-80
TOTAL FLUIDE ATX ou
TOTAL FLUIDE AT 42.
Automatic gearbox MB3
Special oil distributed by CITROEN
GENERAL
(Part No. : 9730 94).
TOTAL FLUIDE AT 42 ou
Automatic gearbox 4 HP 14 et 4 HP 18 All countries Special oil distributed by CITROEN
(Part No. : 9730 94).
Special oil distributed by CITROEN
Automatic gearbox 4 HP 20 et AL4
(Part No. : 9736 22).
Transfer box and differential TOTAL TRANSMISSION X 4
C MATIC gearbox TOTAL FLUIDE T
Oils for power-assisted steering
Power-assisted steering All countries TOTAL FLUIDE ATX
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ALL TYPES LUBRICANTS - TOTAL recommended oils
Engine coolant
CITROEN reference
Packs
GLYSANTIN G 33 REVCOGEL 2000
CITROEN Fluid 2 litres 9979 70 9979 72
All countries
Protection : - 35°C 5 litres 9979 71 9979 73
20 litres 9979 76 9979 74
210 litres 9979 77 9979 75
GENERAL
Synthetic brake fluid
Packs CITROEN reference
CITROEN Fluid 0.5 litre 9979 05
All countries
1 litre 9979 06
5litres 9979 07
CITROEN hydraulic circuit fluid
Mineral fluid for hydraulic circuit - green colour
TOTAL LHM PLUS Packs CITROEN reference
All countries Norms ISO 7308-7309 1 litre ZCP 830 095
Hydraulic circuit rinsing fluid - green colour
TOTAL HYDRAURINCAGE
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LUBRICANTS - TOTAL recommended oils ALL TYPES
Wash / wipe fluid
CITROEN reference
Concentrate : 250 ml 9980 33 ZC 9875 953 U 9980 56
All countries Liquid ready to use : 1 litre 9980 06 ZC 9875 784 U
Liquid ready to use : 5 litres 9980 05 ZC 9885 077 U ZC 9875 279 U
Grease
Norms : NLGI (1)
GENERAL
All countries TOTAL MULTIS EP2 2
TOTAL MULTIS COMPLEX EP2 2
TOTAL MULTIS N4128 1
TOTAL SMALL MECHANISMS
(1) NLGI = National Lubricating Grease Institute.
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ALL TYPES ENGINE OIL CONSUMPTION
I - Oil consumption depends on :
- the engine type.
- how run-in or worn it is.
- the type of oil used.
- the driving conditions.
II - An engine can be considered RUN-IN after:
- 3,000 miles (5,000 km) for a PETROL engine.
GENERAL
- - 6,000 miles (10,000 km) for a DIESEL engine.
III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.
- 0.5 litres per 600 miles (1,000 km) for a PETROL engine
- 1 litre per 600 miles (1,000 km) for a DIESEL engine.
DO NOT WORK BELOW THESE VALUES.
IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.
- This excess oil will be used up rapidly.
- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
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ENGINE
ENGINE SPECIFICATIONS ALL TYPES
Engines : CDZ - HDZ - HDZ/GPL - HFX - KFX - KFX/GPL - KFW
Petrol
All Types
1.0i 1.1i 1.4i
Engine type CDZ HDZ HDZ/GPL HFX KFX KFX/GPL KFW
Cubic capacity (cc) 954 1124 1360
Bore / Stroke 70/62 72/79 75/77
Compression ratio 9.4/1 9.7/1 10.5/1 10.2/1
Power ISO or EEC KW-rpm 37-6000 44.1-6200 43.2-6200 44.1-5500 55-5500
Power DIN (HP-rpm) 50-6000 60-6200 58.8-6200 60-5500 75-5500
Torque ISO or EEC (m.daN-rpm) 7.35-3700 8.75-3800 8.31-3800 9.4-3500 11.1-3400
Torque DIN (mkg-rpm) 7.5-3700 9.1-3800 8.65-3800 -3500 11.5-3400
Max. speed (rpm) 6400 6500 6500
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ENGINE
ALL TYPES ENGINE SPECIFICATIONS
Engines : NFZ – NFT – NFU – NFX - LFX
Petrol
All Types
1.6 i 1.6 i 16 V 1.8 i
SAXO PICASSO
Engine type NFZ NFT NFU NFX LFX
Cubic capacity (cc) 1587 1761
Bore / Stroke 78.5/82 83/81.5
Compression ratio 9.6/1 10.5/1 11/1 10.8/1 9.5/1
Power ISO or EEC KW-rpm 65-5600 70-5700 72-5700 80-5800 8.7-6600 66-5000
Power DIN (HP-rpm) 90-5600 95-5700 98-5700 11-5800 120-6600 90-5000
Torque ISO or EEC (m.daN-rpm) 13.5-3000 13.5-3500 14.7-4000 14.5-5200 14.7-2600
Torque DIN (mkg-rpm) 14-3000 13.8-3000 ?-3500 15.6-4000 15-5200 15.2-2600
Max. speed (rpm) 6100 6300
60
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ENGINE
ENGINE SPECIFICATIONS ALL TYPES
Engines : LFY - LFY/GPL - 6FZ - RFN - RFS - RFV
Petrol
All Types
1.8i 16V 2.0i 16V
Engine type LFY LFY/GPL 6FZ RFN RFS RFV
Cubic capacity (cc) 1761 1749 1997 1998
Bore / Stroke 83/81.4 82.7/81.4 85/88 86/86
Compression ratio 10.4/1 10.8/1 10.4/1
Power ISO or EEC KW-rpm 81-5500 72-5500 85-5500 99-6000 12-6500 97.4-5500
Power DIN (HP-rpm) 112-5500 109-5500 115-5500 136-6000 167-6500 135-5500
Torque ISO or EEC (m.daN-rpm) 15.5-4250 16.3-4000 19-4100 19.3-5500 18-4200
Torque DIN (mkg-rpm) 16.1-4250 16.6-4000 19.8-4100 20-5500 18.7-4200
Max. speed (rpm) 6400 6500 6800
61
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ENGINE
ALL TYPES ENGINE SPECIFICATIONS
Engines :VJZ - VJX - VJY - WJZ - DHV - RHY
Diesel
All Types
1.5 D 1.9 D 1.9TD 2.0 HDi
Engine type VJZ VJX DHY WJZ DHY RHY
Cubic capacity (cc) 1527 1527 1868 1905 1997
Bore / Stroke 77/82 77/82 82.2/88 83/88 85/88
Compression ratio 23/1 23/1 23/1 21.8/1 17.6/1
Power ISO or EEC KW-rpm 42-5000 40-5000 51-4600 66-4000
Power DIN (HP-rpm) 58-5000 55-5000 70-4600 90-4000
Torque ISO or EEC (m.daN-rpm) 9.5-2250 12.5-2500 19.6-2250 20.5-1900
Torque DIN (mkg-rpm) 9.68-2250 14-2500 20.5-2250 21.4-1900
Max. speed (rpm) 5450 5350 4600 5300
62
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) ALL TYPES
CYLINDER HEAD (mm)
Engine type CDZ HDZ-HFX KFX-KFW NFZ NFU-NFX VJZ-VJY-VJX
Maximum permissible bow 0.05
Gasket surface regrinding - 0.20
TIGHTENING TORQUES ( m.daN)
Crankshaft Pre-tightening 2 ± 0.2 2 ± 0.2
bearing screws Loosening
Tightening
Angular tightening 45° 50° ± 5°
Tightening
Pre-tightening
Connecting rod Loosening
screws Tightening 3.8 ± 0.4
Angular tightening
Pre-tightening
Flywheel screw Tightening 6.5 ± 0.7
Angular tightening
Crankshaft Tightening
pinion screw Angular tightening
Crankshaft Pre-tightening 7 ± 0.7
pulley screw Tightening 10 ± 1 45° ± 4°
Camshaft Pre-tightening 8 ± 0.8 4 ± 0.4
pulley screw Angular tightening 20° ± 2°
Camshaft hubs 8 ± 0.8
Camshaft end pulley screw
Camshaft hub Pre-tightening 1 ± 0.1 2.5 ± 0.2
screw Tightening
63
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ENGINE
ALL TYPES SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )
CYLINDER HEAD (mm)
Engine type LFX LFY 6FZ RFN RFV RFS WJZ RHY
Maximum permissible bow 0.05 0.03
Gasket surface regrinding - 0.20 - 0.30 - 0.20 - 0.40
TIGHTENING TORQUES ( m.daN)
Pre-tightening (1) Ø 11 : 2 ± 0.1 2.5 ± 0.3
1 ± 0.1
Loosening (2) Ø 6 :
1 ± 0.1
Crankshaft Tightening 5.5 ± 0.5 (only) 7 ± 0.7 8.5 ± 0.8 7 ± 0.7
bearing screws Ø 11 to 1 ± 0.1
then to 2 ± 0.1 60° ± 6°
Angular tightening Ø 11 to 70° ± 5° 60° ± 6°
Tightening Ø 6 to 1 ± 0.1
Pre-tightening 4 ± 0.4 1 ± 0.1 4 ± 0.4 2 ± 0.2
Connecting rod Loosening 180° (1/2 turn)
screws Tightening 2 ± 0.2 2.3 ± 0.2 2.3 ± 0.2 2± 0.2
Angular tightening 70° ± 7° 46° ± 5° 46° ± 4.6° 70° ± 7° 70° ± 7°
Pre-tightening 0.8 ± 0.1
Flywheel screw Tightening 5 ± 0.5 2 ± 0.2 2 ± 0.2 5 ±0.5 5 ± 0.5
Angular tightening 26 ° ± 3° 21° ± 3°
Crankshaft Tightening 4 ± 0.4
pinion screw Angular tightening 53 ° ± 4°
Crankshaft Pre-tightening 1.5 ± 0.2 4±
pulley screw Tightening 12 ± 1.2 2.1 ± 0.2 12 ± 1.2 60° ±
Camshaft pulley Pre-tightening 4 ± 0.4
screw Angular tightening 51° ±5°
Camshaft end pulley screws 5.5 ± 0.5 5.5 ± 0.5 4.5 ± 0.5
Camshaft hub Pre-tightening 3 ± 0.3
screw Tightening 7.5 ± 0.7
64
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) TUD - XU
Engines : LFY -RFV - RFS - VJZ - VJY - VJX
SAXO XSARA
VJZ-VJY-VJX LFY-RFV-RFS
- Pre-tighten 0.4 - Pre-tighten 0.5
- Tighten 0.7 - Tighten 1
B1DP03BC B1DP01YD
65
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ENGINE
ENGINE
TU - TUD - All Types CYLINDER HEAD
Engines : CDZ – HDZ – HFX – KFX - KFW – NFZ – NFT – NFU - NFX – VJZ – VJY – VJX
IDENTIFICATION OF THE CYLINDER HEAD GASKET
Engine type CDZ HDZ - KFX HFX - KFW NFZ - NFT NFU - NFX VJZ- VJY - VJX
Identification marks (Notch on cylinder head gasket) *
1 0 1 1 1 1
2 0 0 0 1 1
Thickness 0 0 0 1 1
3
4 0 0 1 1 0
A 0
CURTY B 0
D 0
A 1 1
MEILLOR B 1 1
D 0 0
Suppliers
A 1
ELRING B 0
D 1
A 1
REINZ B 0
D 0 0 = Without notch 1 = One notch
Material C 0 (With asbestos) - 1 (Without asbestos) *
Repairs R 0 (Standard gasket) - 1 (Repair gasket) B1BP10KC
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ENGINE
CYLINDER HEAD (continued) TU - TUD - All Types
Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT - NFU - NFX - VJX - VJY - VJX
Cylinder head tightening (m.daN) Cylinder head bolts
CDZ - HDZ - HFX - KFX
KFW - NFZ - NFT
- Pre-tightening 2
- Angular tightening 240° ± 5°
VJZ - VJY - VJX Note : Oil the threads and under the heads
of the cylinder head bolts.
- Pre-tightening 4 (Use engine oil or Molykote G Rapid Plus).
- Angular tightening 300° ± 5°
B1BP10LC
NFU - NFX
- Pre-tightening 2
B1DP059C
- Angular tightening 260° ± 5°
X = MAXIMUM reusable length
CDZ - HDZ - HFX - KFX -
VJX - VJY - VJX NFU - NFX
KFW - NFZ - NFT
B1DP13NC X = 175.5 ± 0.5 mm X = 197.1 mm X = 122.6 mm
67
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ENGINE
XU - All Types CYLINDER HEAD
Engine : 6FZ
Identification of the cylinder head gasket
Nominal dimension Repair dimension
Marking zone
"d" 4–5 2–4–5
Marking zone
"e" R1 R2 R3
Gasket thickness 0.8 1
(mm) 1.1 1.3
Supplier MEILLOR
Marking
" d " Marking zone
" e " Marking zone
NOTE : 3 layer metallic gasket.
B1DP183D
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ENGINE
CYLINDER HEAD (continued) EW 10 - All Types
Engine : 6FZ
Cylinder head tightening (m.daN) Cylinder head bolts
6FZ
Pre-tightening 1.5 ± 0.2
Tightening 5 ± 0.2
Loosening 360 ° (1 turn)
Tightening 2 ± 0.2
Angular tightening 285° ± 5°
B1DP16FC
A = Washer thickness : 4 ± 0.2 mm.
X = Length under heads of new bolts = 144.5 ± 0.5 mm.
NOTE : Oil the threads and
under the heads of the cylinder X = MAXIMUM reusable length
head bolts. (Use engine oil or
Molykote G Rapid Plus). 6FZ
B1DP05BC X= 147 mm
69
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ENGINE
EW 10 - All Types CYLINDER HEAD (continued)
Engine : RFN
Identification of the cylinder head gasket
Nominal dimension Repair dimension
Marking zone
"d" 4–5 2–4–5
Marking zone
"e" R1 R2
Gasket thickness 0.8 1.1
(mm) 1.4
Supplier MEILLOR
Multilayer metallic gasket
B1DP183D
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ENGINE
CYLINDER HEAD (continued) EW 10 - All Types
Engine : RFN
Cylinder head tightening (m.daN) Cylinder head bolts
RFN
Pre-tightening 1.5 ± 0.1
Tightening 5 ± 0.1
Loosening 360°± 2°
Tightening 2 ± 0.75
Angular tightening 285° ± 5°
B1DP16FC
A = Washer thickness : 4 ± 0.2 mm.
X = Length under heads of new bolts = 144.5 ± 0.5 mm.
NOTE : Oil the threads and
under the heads of the cylinder X = MAXIMUM reusable length
head bolts. (Use engine oil or
Molykote G Rapid Plus). RFN
B1DP05BC X= 147 mm
71
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ENGINE
XU - All Types CYLINDER HEAD
Engines : LFX - LFY - RFV - RFS
IDENTIFICATION OF THE CYLINDER HEAD GASKET
Engine type LFX LFY RFV RFS
Identification marks (Notch on cylinder head gasket) *
A 1
B 0
CURTY C 0
D 0
E 0
Suppliers
A 0 0 1
B 1 0 0
MEILLOR C 0 1 1
D 0 0 0
E 0 0 0
0 = Without notch
*
1 = One notch
B1BP004C
72
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ENGINE
CYLINDER HEAD (continued) XU - All Types
Engines : LFX - LFY - RFV - RFS
Cylinder head tightening (m.daN) Cylinder head bolts
LFX - LFY
- Pre-tightening 6
- Loosening YES
- Tightening 2
- Angular tightening 300°
Note : Oil the threads and under
the heads of the cylinder head
bolts. (Use engine oil or
Molykote G Rapid Plus).
B1DP13PC
RFV - RFS X = MAXIMUM reusable length
- Pre-tightening 3.5
- Loosening NO LFX LFY RFV - RFS
- Tightening 7
- Angular tightening 160°
B1DP05BC 171.5 mm 160.5 mm 112 mm
73
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ENGINE
DW8 - All Types CYLINDER HEAD
Engine : WJZ
Identification of the cylinder head gasket
Piston Thickness Number Number WJZ
Engine stand-proud (mm) of holes of holes
type
(mm) (*) ± 0.04 at A at B
0.51 to 0.55 1.26 1
0.55 to 0.59 1.30 2
WJZ 0.59 to 0.63 1.34 2 3
0.63 to 0.67 1.38 4
0.67 to 0.71 1.42 5
(A) = Engine identification.
(B) = Thickness identification.
(*) = Take the highest piston as a reference point.
B1DP14QD
74
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ENGINE
CYLINDER HEAD XUD - All Types
Engine : DHY
Identification of the cylinder head gasket
Thickness
Piston Marking
Engine type (mm)
stand-proud (mm) (B)
± 0.06
0.56 to 0.67 1.36
0.68 to 0.71 1.40
DHY 0.72 to 0.75 1.44
0.76 to 0.79 1.48
0.80 to 0.83 1.52
(A) = Engine identification.
(B) = Thickness identification.
Engine Ident. (A) Ident. (B)
B1BP10TC DHY 3 notches 1 to 5 notches
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ENGINE
DW10 - All Types CYLINDER HEAD
Engine : RHY
Identification of the cylinder head gasket
Piston
Engine Thickness Number of notches
stand-proud
type (mm) at A
(mm)
0.47 to 0.605 1.30 ± 0.06 1
0.605 to 0.655 1.35 ± 0.06 2
RHY 0.655 to 0.705 1.40 ± 0.06 3
0.705 to 0.755 1.45 ± 0.06 4
0.755 to 0.83 1.50 ± 0.06 5
B1DP15AD
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ENGINE
CYLINDER HEAD (continued) XUD - DW8 - DW10 - All Types
Engines : WJZ – DHY - RHY
Cylinder head tightening (m.daN) Cylinder head bolts
WJZ WJZ DHY RHY
- Pre-tightening 2
- Tightening 6
- Angular tightening 180°
DHY-RHY
- Pre-tightening 2
- Tightening 6
- Angular tightening 220°
Note : Oil the threads and under the
heads of the cylinder head bolts. (Use X = MAXIMUM reusable length
engine oil or Molykote G Rapid Plus). WJZ DHY RHY
B1DP05BC B1DP13PC B1DP14NC B1DP15EC 125.5 mm 150.2 mm 133.3 mm
77
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ENGINE
ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
Tools !
!
!
4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5)
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT ALL TYPES
Engines : All Types Petrol and Diesel
TOOLS
- Belt tension measuring instrument : 4122-T. (C.TRONIC 105.5)
- WARNING : If using tool 4099-T (C.TRONIC 105) refer to the correspondence table on page 57.
ESSENTIAL.
- Before refitting the auxiliary equipment drive belt, check that:
1) The roller(s) rotate freely (no play or stiffness)
2) The belt is correctly engaged in the grooves of the various pulleys.
79
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ENGINE
SAXO AUXILIARY EQUIPMENT DRIVE BELT
Engines : CDZ – HDZ – HFX – (KFX – KFW) Saxo – (NFZ) Saxo - NFT
Without air conditioning With air conditioning.
- Fit the tool 4122-T. - Fit the tool 4122-T.
- Tighten the tensioning screw (3) - Tighten the tensioning screw (5)
to obtain : to obtain :
55 ± 3 SEEM units. 120 ± 3 SEEM units.
- Tighten the screws (2) and (1). - Tighten the screws (6) and (4).
- Remove the tool 4122-T. - Remove the tool 4122-T.
B1BP10UC B1BP10WC B1BP10VC B1BP10XC
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA PICASSO
Engine : NFZ (Xsara Picasso)
Without air conditioning
Tools.
[1] Plyers for removing plastic pegs : 7504 –T.
[2] Belt tension measuring instrument : 4122 –T.
[3] TORX spanner
Remove.
- Release the central screw (1) tool [3].
- Detension the tensioner roller (2), (flat spanner 27 on flat).
- Remove the belt.
Refit.
- Position the belt.
- Hold the belt in position using the tensioner roller (2).
- Pre-tension the belt 120 SEEM units, tool [2].
- Lock the central screw (1) tool [3].
- Remove the tool [2].
- Rotate the crankshaft 2 to 4 times.
- Check the tension, 120 SEEM units.
- If not, restart the operation.
B1BP234C
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ENGINE
XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT
Engine : NFZ (Xsara Picasso)
With air conditioning.
Tools.
[1] Plyers for removing plastic pegs : 7504 –T.
[2] Belt tension measuring instrument : 4122 –T.
[3] 10 mm square (drain spanner).
[4] TORX spanner.
Remove.
- Detension the automatic tensioner, tool [3].
- Place a Ø 6 mm peg at (a) to immobilise the automatic tensioner.
- Remove the belt.
Refit.
- Position the belt
- Detension the automatic tensioner, tool [3].
- Remove the Ø 6 mm peg.
- Release the automatic tensioner.
- Remove the tool [3].
B1BP235C
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : KFX - KFW (Xsara)
Alternator With air conditioning.
[1] Belt tension measuring instrument : [1] Belt tension measuring instrument :
4122-T 4122-T
- Tension the belt using the screw (2). - Tension the belt using the screw (4).
- Tension should be : - Tension should be:
102 ± 7 SEEM units. 102 ± 7 SEEM units.
- Tighten the screws (1). - Tighten the screws (3).
Power-assisted steering Power steering and air con.
- New belt
- New belt 100 SEEM units.
100 SEEM units.
- Reused belt
- Reused belt 75 SEEM units.
75 SEEM units.
B1BP1B2C B1BP122C B1BP1B3C B1BP124C
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ENGINE
SAXO - XSARA AUXILIARY EQUIPMENT DRIVE BELT
Engines : NFX - NFU
Without air conditioning
(1) Tensioner roller fixing screw.
(2) Tensioning screw.
- New belt : 120 SEEM units.
- Reused belt : 86.5 ± 3.5 SEEM units.
B1BP1AMC
With air conditioning.
(3) Tensioner roller fixing screw.
(4) Tensioning screw.
- New belt : 120 SEEM units.
- Reused belt : 86.5 ± 3.5 SEEM UNITS.
NOTE : Removal of the tensioner roller makes it necessary to remove the plate with the upper fixing screw (5).
B1BP1ANC
84
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT SAXO- XSARA
Engine : VJZ - VJY - VJX
Without air conditioning
- (6) Roller support fixing screw.
- (7) Tensioning screw.
- Pre-tension the belt (8) to : 120 SEEM units.
- Rotate the crankshaft by 3 turns (Direction of rotation).
- Adjust the belt (8) tension to : 120 SEEM units.
- Tighten the screws (6) to : 2.5 m.daN.
- Run the engine for 10 mm.
- Check the tension. B1BP11EC
With air conditioning.
- (3) Roller support fixing screw
- (5) Tensioning screw.
- Pre-tension the belt (4) to : 120 SEEM units.
- Rotate the crankshaft by 3 turns (Direction of rotation).
- Adjust the belt (4) tension to : 120 SEEM units.
- Tighten the screws (3) to : 2.5 m.daN.
- Run the engine for 0 mm.
- Check the tension.
B1BP11DC
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ENGINE
XSARA AUXILIARY EQUIPMENT DRIVE BELT
Engines : LFX - LFY - RFV
Without air conditioning
- (3) and (5) Roller support fixing screws.
- (6) Tensioning screw.
- Tighten the belt, by loosening the screw (6) to : In SEEM units.
LFX LFY RFV
100 ± 10 120 ± 10 100 ± 10
- Tighten the screws (3) and (5).
- Rotate the crankshaft by 4 turns (Direction of rotation).
- Loosen the screws (3) and (5).
- Tighten the belt, by loosening the screw (6) to : In SEEM units.
LFX LFY RFV
115 ± 5 120 ± 10 105 ± 10
- Tighten the screws (3) and (5) to 2 m.daN.
B1BP00HC B1BP00IC
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : RFS
Without air conditioning
TOOLS
[1] Belt tension measuring instrument 4122-T
- (1) Tensioning screw.
- (2) Roller support fixing screw (3).
- Lightly tighten the screws (2).
- Place the tool [1] on the belt.
- Tension the belt using the screw (1).
• Reused belt 90 SEEM units.
• New belt 120 SEEM units.
- Tighten the screws (2) to 2 m.daN.
- Remove the tool [1].
- Rotate the crankshaft by 3 turns (direction of rotation).
- Check the belt tension using the tool [1], and adjust (if necessary).
B1EP12XC B1EP12YC
87
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ENGINE
XSARA AUXILIARY EQUIPMENT DRIVE BELT
Engines : LFX - LFY - RFV - RFS
With air conditioning.
- Fit the drive belt.
- The tensioner roller (1).
- Tightening des vis (3) à 2 m.daN.
- Move the tensioner roller (1) using the tool (9.52 mm square drive (3/8) ) at (2), in order to remove
the tool or locking peg (Ø 4 mm) at (4).
- Slowly release the tensioner roller (1) so that the roller (5) presses against the belt.
B1BP1HJC
88
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : RFV
With air conditioning.
- Loosen :
- The screws (4) of the tensioner roller (13 mm angle spanner).
- The screw (3).
- Tendre la courroie en agissant sur la vis (3) pour obtenir une valeur de :
- New belt : 120 SEEM units.
- Reused belt : 90 SEEM units.
- Tighten the screws (4) to 2 m.daN.
- Rotate the crankshaft by 4 turns (direction of rotation).
- Adjust the belt tension (if necessary ).
B1EP05FC
89
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ENGINE
XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT
Without air conditioning Engines : 6FZ - RFN With air conditioning.
Tools
[1] Plyers for removing plastic pegs : 7504-T
Remove the belt.
- Detension the belt (3) by turning the screw (2) of the tensioner roller (1)
(anti-clockwise).
- The screw (2) (WARNING : not left hand screw).
- Remove the belt (3), while keeping the tensioner roller (1) tight.
Refit the belt.
- Refit the belt (3), while keeping the tensioner roller (1) tight.
- Release the tensioner roller (1).
B1BP23PC B1BP23QC B1BP23PC B1BP23RC
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engines : WJZ
Without power-assisted steering
Tools :
[1] Belt tension measuring instrument : 4122-T.
Removal.
- Loosen the screws (2).
- Tighten the screw (1) until it is against its stop.
- Remove the belt.
Refitting.
- Refit the belt.
- Fit the tool [1] on the belt at "d".
- Tighten the screw (1) to obtain : 106 ± 10 SEEM units.
- Tighten the screws (2) to 2 m.daN.
- Remove the tool [1].
B1BP1SDC B1BP1SEC
91
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ENGINE
XSARA AUXILIARY EQUIPMENT DRIVE BELT
Engine : WJZ
Without power-assisted steering With air conditioning.
Tools :
[1] Belt tension measuring instrument : 4122-T.
Removal.
- Loosen the screws (1).
- Tighten the screw (2) until it is against its stop.
- Remove the belt.
Refitting.
- Refit the belt.
- Fit the tool [1] at "e".
- Tighten the screw (2) to obtain : 106 ± 10 SEEM units.
- Tighten the screws (1) to 2 m.daN.
- Remove the tool [1].
B1BP1SFC B1BP1SGC
92
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : WJZ
Power-assisted steering Without air conditioning
Tools :
[1] Belt tension measuring instrument : 4122-T.
Removal.
WARNING : If the belt is to be reused, measure the tension before removal.
- Loosen :
- The screw (1).
- The nut (2).
NOTE : The tensioner arm (3) must be against the alternator.
- Remove the belt.
B1BP1SHD
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ENGINE
XSARA AUXILIARY EQUIPMENT DRIVE BELT
Engine : WJZ
Power-assisted steering, without air conditioning (continued)
Refitting.
- Refit the belt.
- Place the tool [1] on belt at "f".
WARNING : Position tool [1], with the knob downwards.
- Tighten the nut (2) to obtain a value of :
Reused belt :
Keep the value taken at removal.
New belt :
Tension should be 110 SEEM units.
- Tighten the screw (1) to 9.5 m.daN.
- Check belt tension (tool [1] ).
Tension should be 144 ± 3 SEEM units.
- Remove the tool [1].
- Start the engine and run it for 10 seconds.
- Stop the engine.
- Place the tool [1] on the belt at "f".
- Tension should be 130 ± 4 SEEM units.
- Remove the tool [1].
B1BP1SJD
94
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : WJZ
Power-assisted steering With air conditioning.
Tools :
[1] Dynamic tensioner peg (-) 0188 H.
[2] Belt tension measuring instrument 4122-T.
Removal
- Peg the dynamic tensioner (1) at "a", using tool [1].
- Loosen the screw (2) of the roller (3).
- Turn the roller (3) backwards.
- Remove the belt.
NOTE : If it can not be pegged at "a" :
- Loosen the screw (2) of the roller (3).
- Using a 7 mm square drive, turn the roller (3) at "b".
- Peg the tensioner (1) at "a", using tool [1].
NOTE : If the belt is broken :
- Support the engine using a jack (insert a wooden block between the housing and the jack).
- Remove the right engine support.
- Using a square drive at (b) turn the tool (3) in the direction of the arrow "a", so that it can be
pegged at "a" using the tool [1].
B1BP1SKC
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ENGINE
XSARA AUXILIARY EQUIPMENT DRIVE BELT
Engine : WJZ
Power-assisted steering with air conditioning (Continued)
Refitting.
- Refit the belt.
- Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free.
- Tighten the screw (2).
- Remove the tool [1].
B1BP1SLC
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : DHY
Without air conditioning
[2] Belt tension measuring instrument : 4122-T
- Tension the belt by loosening the screw (4) to obtain :
115 ± 10 SEEM units
- Tighten the screws (1) and (3).
- Rotate the crankshaft by 4 turns (direction of rotation).
- Loosen the screws (1) and (3).
- Tension the belt to :
115 ± 10 SEEM units (if necessary)..
- Tighten the screws (1) and (3) to 2 m.daN.
B1BP10GC B1BP10HC
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ENGINE
XSARA AUXILIARY EQUIPMENT DRIVE BELT
Engine : DHY
With air conditioning
Tools
(1) Peg : 7019-T.
.- Loosen the screws (1).
- Tighten or loosen the screw (2) until holes "a" and "b" are superimposed.
- Place the peg [1] : (in the hole "a").
- Tighten the screw (2) until it is against its stop.
- Loosen the screw (2), in order to remove the peg [1].
- Tighten the screws (1) to 2 m.daN.
B1BP1HHC
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO
Engine : RHY
Without air conditioning
Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] Ø 4 mm peg : (-).0188.Q1
[3] Ø 2 mm peg : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z
REMOVAL
Re-used belt
WARNING : Mark the direction the belt was fiited in case of re-use of the same belt.
- Compress the tensioner roller (2) by action at "a" (in anti-clockwise direction), tool [4].
- Keep the tensioner roller (2) compressed and remove the belt.
No re-use of belt.
- Compress the tensioner roller (2) by action at "a" (in anti-clockwise direction), tool [4].
- Peg using tool [2], at "b".
- Keep the tensioner roller (2) compressed and remove the belt.
- Loosen the screw (1).
B1BP1YKD
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ENGINE
XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT
Engine : RHY
Without air conditioning (Continued)
REFITTING.
Re-used belt.
- Compress the tensioner roller (2) by action at "a" (in anti-clockwise direction), tool [4].
-Refit the belt.
WARNING : Respect the belt-fitting direction.
- Remove the tool [4].
New belt.
Refit the belt.
- Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging at "b".
- Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 m.daN.
Remove the tool [2].
- Rotate the crankshaft 4 times in the direction of rotation.
- Check that it is possible to peg at "b", tool [3].
- If not possible to peg, restart the adjustment.
B1BP1YMD
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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO
Engine : RHY
With air conditioning
Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] Ø 4 mm peg : (-).0188.Q1
[3] Ø 2 mm peg : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z
REMOVAL
Re-used belt.
WARNING : Mark the direction the belt was fitted in case of re-use of the same belt.
- Compress the tensioner roller (7) by moving it at "c" (in anti-clockwise direction), tool [4].
- Hold the tensioner roller (7) compressed and remove the belt.
No re-use of belt.
- Compress the tensioner roller (7) by moving it at "c" (in anti-clockwise direction), tool [4].
- Peg using tool [2], at "d".
- Loosen the screw (6)
- Bring the eccentric roller (5) towards the rear.
- Tighten the screw (6) by hand.
- Remove the belt.
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ENGINE
XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT
Engine : RHY
With air conditioning (Continued)
REFITTING.
Re-used belt.
- Compress the tensioner roller (7) by action at "c" (in anti-clockwise direction), tool [4].
- Refit the belt.
WARNING : Respect the direction belt was fitted.
- Remove the tool [4].
New belt.
- Refit the belt.
- Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging
at "d".
- Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 m.daN.
Remove the tool [2].
- Rotate the crankshaft 4 times in the direction of rotation.
- Check that it is possible to peg at "d", tool [3].
- If not possible to peg, restart the adjustment.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING ALL TYPES
TU XU EW XU
9 1 3 5 7 10
M M+ JP JP+ 14 JP4 JB JP4 J4 J4R J4RS
Engine type CDZ HDZ HFX KFX KFW NFZ NFT NFU NFX LFX LFY 6FZ RFN RFV RFS
SAXO X X X X X X X X
K 09/2000 XSARA X X X X X X
XSARA 09/2000 K X X X X
XSARA PICASSO X X
108 115 122 117 122
See pages : 105 to 107 to to to to to
111 116 126 121 126
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ENGINE
TUD - XUD CHECKING AND SETTING THE VALVE TIMING (continued)
TUD XUD DW
5 9 8 10
B TD B TD
Engine type VJZ VJY VJX DHY WJZ RHY
SAXO X X X
K 09/2000 XSARA X X X X
XSARA 09/2000 K X X
XSARA PICASSO X
See pages : 112 to 114 132 127 to 131 133 to 137
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT
TOOLS
- [1] Flywheel locating peg : 4507-T.A
- [2] Camshaft pulley locating peg : 4507-T.B Tool kit 4507-T
- [3] Square drive : 4507-T.J
- [4] Belt tension measuring instrument : 4122-T
- [5] Rocker plate : 4533-T.Z
CHECKING THE VALVE TIMING.
- Peg the flywheel using the tool [1].
- Peg the camshaft pulley using the tool [2].
SETTING THE VALVE TIMING.
NOTE : Remove the spark plugs, to allow the crankshaft to rotate more freely.
- Rotate the engine by the crankshaft screw (1).
- Peg the camshaft gearwheel.
- Peg the flywheel.
- Loosen the nut (2).
- Totally slacken the belt by moving the tensioner roller.
- Remove the belt.
ESSENTIAL : Check that the tensioner roller rotates freely (no stiffness).
B1EP067C B1EP066C B1EP0668C
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (Continued).
REFITTING THE TIMING BELT.
NOTE : Check that the pegs [1] and [2] are in place.
WARNING : Ensure the belt is fitted in the right direction : The arrows "a" signify the crankshaft direction
of rotation.
Fit :
- The timing belt, with the belt strip "b" well tightened, in the following order:
Crankshaft pinion, camshaft pulley, water pump pulley, tensioner roller.
-The tool [5] (Ensure it is fitted in the right direction in relation to the timing).
- Bring the tensioner roller into contact with the belt.
-Tighten the nut (2).
PRE-TENSIONING THE TIMING BELT.
- Fit the tool [4] on the tightened belt strip "b".
- Loosen the nut (2).
-Turn the roller (3) in an anti-clockwise direction using a square drive to obtain : 44 SEEM units
- Tighten the nut (2) to 2 m.daN.
- Remove the tools [1] [2] and [4].
- Rotate the crankshaft by 4 turns in the normal direction.
ESSENTIAL : Never turn the crankshaft backwards.
B1EP069C B1EP06AC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (Continued).
PRE-TENSIONING THE TIMING BELT (Cont.).
- Ensure the timing is correctly set by refitting the pegs [1] and [2].
- Remove the cylinder head cover.
- Fit the tool [5] (Ensure it is fitted in the right direction in relation to the timing).
ADJUSTING THE BELT FITTING TENSION.
- Fit the tool [4] to the tightened belt strip.
- Loosen the nut (2).
- Slacken the belt (not excessively).
- Tighten the timing belt to obtain : 31 ± 2 SEEM units.
- Tighten the nut (2) to 2.2 m.daN.
- Remove the tools [1] [2] [4] and [5].
CHECKING THE BELT TENSION.
- Rotate the crankshaft by 2 turns in the normal direction of rotation.
- Check that the following components can still be pegged :
- Flywheel.
- Camshaft.
ESSENTIAL : If the components cannot be pegged, repeat the belt tensioning procedure.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : NFX - NFU
TOOLS
- [1] Belt tension measuring instrument : 4122-T
- [2] Flywheel locating peg : 4507-T.A.
- [3] Camshaft pulley locating peg, exhaust : 4533-T.A. C2
- [4] Camshaft pulley locating peg, inlet : 4533-T.A. C1 Tool kit 4507-T
- [5] Tensioning tool : 4707-T.J.
CHECKING THE VALVE TIMING
- Peg the flywheel using the tool [2].
- Peg the exhaust camshaft pulley [3].
- Peg the inlet camshaft pulley [4].
SETTING THE VALVE TIMING
- Peg the flywheel using the tool [2].
- Peg the camshaft pulleys [3] and [4].
B1EP11BC B1EP11CC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : NFX - NFU (continued)
SETTING THE VALVE TIMING
- Remove the tools [1], [2], [3] and [4].
- Loosen the six pulley screws (1) on the hubs.
(There should be a slight amount of friction between the screws and the pinions).
- Check that the rollers (2) and (3) rotate freely.
NOTE : The belt bears three identification marks *(a), (b) and (c), facing its own teeth (1), (52) and (72) respectively.
* (Identification marks = white paint lines on the back of the belt facing the corresponding teeth).
- Refit the belt.
- Line up mark (A) on the belt with groove (D) of the pinion (4).
- Hold the belt against the pinion (4).
B1EP11DC B1EP11EC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : NFX - NFU (continued)
SETTING THE VALVE TIMING
- Turn the two pulleys (1) clockwise to the end of the slots.
- With the belt strip (e) fully tensioned, place the belt over the pulley, first exhaust side, then inlet side, while
ensuring that marks (b) and (c) on the belt are aligned with marks (f) on the pulleys.
- Hold the belt in this position, and engage it over the water pump pinion and the tensioner roller.
- Fit the tool [1] on the belt strip (e).
- Rotate the roller (2) (using tool [5]) in an anti-clockwise direction, to obtain: 63 SEEM units.
- Tighten the roller (2) to 2 m.daN.
- Tighten the six screws (5) to 1m.daN.
ESSENTIAL : Check that :
- The camshaft pulleys (1) are not at the end of the slots (by removing a screw).
- The markings on the belt are aligned with the markings on the crankshaft and camshaft pulleys.
- If not, repeat the setting procedure.
B1EP11FC B1EP11GC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : NFX - NFU (Continued)
SETTING THE VALVE TIMING
- Remove the tools [1] , [2] , [3] and [4].
- Rotate the engine by four turns in the normal direction. (do not turn backwards).
- Peg the flywheel [2].
- Loosen the six screws (5), while ensuring there is still a slight amount of friction with the pulley.
- Peg the camshaft hubs using pegs [3] and [4].
WARNING : In certain cases, it may be necessary to slightly turn the camshaft using the hub fixing screw.
- Fit the tool [1].
- Loosen the tensioner roller screw (2).
- Rotate the roller (2) (using tool [5]) in an anti-clockwise direction to obtain : 37 SEEM units.
- Tighten the tensioner roller screw (2) to 2 m.daN.
- Tighten the six pulley screws (1) to 1m.daN.
- Remove the tools.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : VJZ - VJY - VJX
TOOLS
- Belt tension measuring instrument : 4099-T or 4122-T
- Flywheel locating peg : 4507-T.A.
- Injection pump pulley locating peg : 4527-T. S1 Tool kit 4507-T
- Camshaft pulley locating peg : 4527-T. S2
- Tensioning lever. : 4507-T.J.
- Pinion locking tool : 6016-T.
CHECKING THE VALVE TIMING
- Peg : the flywheel, the injection pump pulley, the camshaft pulley.
SETTING THE VALVE TIMING
- Peg : the flywheel, the injection pump pulley, the camshaft pulley.
- Loosen the tensioner roller, and remove the belt.
ESSENTIAL: Check that the tensioner and guide rollers rotate freely (no stiffness). If not, replace
the roller(s).
- Loosen the screws (1) and (3) (lock the pulley with tool 6016 - T).
- Position pulleys (2) and (4) to the end of the slots (without tightening the screws (1) and (3)).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : VJZ - VJY - VJX (Continued)
SETTING THE VALVE TIMING
- Fit the belt in the following order :
The crankshaft pinion, the injection pump pulley, the camshaft pulley, the water pump pinion.
WARNING : When positioning the belt on the injection pump and camshaft pulleys, they should
be turned in the opposite direction of rotation so as to engage the nearest tooth.
- Pre-tension (belt strip slightly tightened).
NOTE : Check that the pulley fixings are not at the end of the slots (adjust by one tooth if necessary).
- Tighten the screws (1) and (3) to 0.5 m.daN, loosen by 180°.
(Gently tighten the screws (1) and (3) by hand).
- Loosen the tensioner roller.
- Tension to 100 SEEM units.
- Tighten the tensioner roller to 2.3 m.daN.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : VJZ - VJY - VJX (Continued)
SETTING THE VALVE TIMING
- Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T).
- Remove the tools.
- Rotate the engine by 10 turns.
- Peg : The flywheel, the pulleys (2) and (4).
NOTE : If necessary, lightly slacken the belt (with the tensioner roller).
- Loosen the screws (1) and (3) by 360° (gently tighten the screws (1) and (3) by hand).
- Set a final tension of 55 ± 5 SEEM units.
- Tighten the tensioner roller, and the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T).
- Remove the tools.
- Rotate the engine by two turns.
NOTE : If the belt is not correctly located on the pinions and pulleys, rotate it by an additional two turns.
- Peg the flywheel.
- Check that the camshaft and injection pump pulleys are correctly pegged.
WARNING : If the visual check is not correct, repeat the setting operation.
- Remove the tools.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : LFX
TOOLS
- Belt tension measuring instrument : 4099-T or 4122-T
-
-
-
Camshaft pulley locating peg
Crankshaft locating peg
Square drive
:
:
:
7004-T.G.
7014-T.N.
7017-T.W.
Tool kit 7004-T
CHECKING THE VALVE TIMING
- Remove the protective covers.
- Peg the camshaft pulley at "a" using the tool 7004-T.G.
- Peg the crankshaft at "b" using the tool 7014 - T.N.
SETTING THE VALVE TIMING
- Check that the pegs can be engaged correctly at "a" and "b".
- Fit the belt in the following order : camshaft pulley, crankshaft pinion, water pump pinion, tensioner roller.
- Peg the camshaft pulley at "a" and the crankshaft pinion at "b" .
- Remove the peg at "b" only.
- Bring the tensioner roller (2) into contact with the belt.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : LFX (Continued)
SETTING THE VALVE TIMING
- Fit the tension measuring tool to the middle of the belt strip "c".
- Turn the tensioner roller (2) (anti-clockwise direction) using the tool 7017-T.W to obtain the following
measurement : 30 ± 2 SEEM units.
- Tighten the screw (1) to 2 m.daN.
- Remove the tools.
- Rotate the crankshaft by two turns (do not turn backwards).
- Check the setting by positioning the pegs at "a" and "b".
- Remove the pegs.
CHECKING THE TENSION
- Rotate the crankshaft by two turns (do not turn backwards).
- Peg the camshaft pulley at "a".
- Fit the tension measuring tool on the belt strip at "c".
- The tension measurement should be 44 ± 2 SEEM units.
(If the measurement is not correct, repeat the tensioning procedure).
- Remove the tools.
B1EP07RC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : 6FZ - RFN
TOOLS
[1] Camshaft setting pegs : (-).0189.A
[2] Crankshaft setting peg : (-).0189.B
[3] Belt locking pin : (-).0189.K Tool kit C.0189.
[4] Angular tightening adaptor : 4069-T
[5] Hub immobilising tool : 6310-T
CHECKING THE VALVE TIMING..
- Turn the engine by the crankshaft pinion screw (3) to bring it to pegging position.
- Peg the crankshaft, using tool [2].
- Peg the camshaft pulleys, using tools [1].
NOTE : The pegs [1] must go in without effort.
B1BP22SC B1BP25PC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : 6FZ - RFN
CHECKING THE VALVE TIMING. (continued).
WARNING : If the pegs do not engage without effort, restart the fitting and tensioning of the timing belt
(see below).
SETTING THE VALVE TIMING
Remove
- Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3).
- Turn the engine by the screw (13) of the pinion (12) to bring it to pegging position.
- Peg the pulleys (8) and (9) using tools [1].
- Peg the pinion (12) using tool [2].
- Loosen the screw (7) of the tensioner roller (6).
- Turn the tensioner roller (6) (clockwise).
- Remove the timing belt (10).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : 6FZ - RFN
Refit (continued)
- Refit the belt (10) on the pinion (12).
- Hold the belt (10) with tool [3].
- Position the belt (10) in the following order :
- The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the
tensioner roller (6).
NOTE : Make sure that the belt (10) is as flush as possilble with the outer face of the various pinions and rollers.
-Remove the tools [3] and [1].
Timing belt tension
Adjusting the tension
- Turn the roller (6) in the direction of the arrow "b"; using an Allen key at "a".
-Position the index "c" in its maximum setting at "d".
IMPERATIVE : The index "c" must stand proud of the notch "f" by an angular value of 10°. If it does not,
replace the tensioner roller (6) or the timing belt and the tensioner roller (6).
- Bring the index "c" to its adjusting position "f" by turning the tensioner roller (6) in the direction of the
arrow "e";
WARNING: The index "c" must not stand proud of the notch "f" : if it does, restart the timing belt tensioning operation;
IMPERATIVE : The tensioner roller (6) must not turn while its fixing is being tightened up. If it does, recom-
mence the adjusting operation.
B1EP14JD B1EP14KC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : 6FZ - RFN
Adjusting the tension (continued).
- Tighten the screw (7) of the the tensioner roller (6) to 2.1 ± 0.2 m.daN.
IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15° below the level of the cylinder
head gasket "g". If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6).
Refit (continued).
- Remove the tools [1] and [2].
- Turn the crankshaft 10 times in the normal direction of rotation.
IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt.
- Peg the inlet camshaft pulley, using the tool [1].
Checks.
Timing belt tension
MPERATIVE : Check the position of the index "c", it should be facing the notch "f". If the position of index "c" is
not correct, restart the adjustment of its position.
Positioning of the crankshaft.
- Fit tool [2].
- As long as it is possible to fit tool [2], continue with the refit operations.
IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : 6FZ – RFN
Checks (continued)
Repositioning the flange.
- Immobilise the crankshaft using tool [5].
- Loosen the screw (13).
- Release the pinion (12) of the crankshaft.
- Bring the flange (14) to the pegging position; using tool [5].
- Fit the tool [2].
- Immobilise the crankshaft using tool [5].
- Tighten screw (13) to 4 ± 0.4 m.daN, then angular tighten 53° ± 4° with tool [4].
- Remove tools [1], [2] and [5].
Refit :
- The lower valve cover (3).
- The upper valve cover (4).
- The crankshaft pulley (1).
- The screws (2).
- Pretighten the screws (2) to 1.5 m.daN.
- Tighten the screws (2) to 2.1 ± 0.5 m.daN.
B1EP14PC B1BP23XC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : LFY - RFV - RFS
TOOLS
[1] Belt tension measuring instrument : 4122-T
[2]
[3]
Camshaft pulley locating peg
Crankshaft locating peg
:
:
9041-T.Z
7014-T.N Tool kit 7004-T
[4] Camshaft pulley locking peg : 4200-T.G
[5] Tensioner spanner : 7017-T.W Tool kit 7004-T
[6] Toothed sector for locking the flywheel : 9044-T
CHECKING THE SETTING
- Turn the engine by the crankshaft screw (1).
- Peg the crankshaft using the tool [3].
ESSENTIAL : Check that the crankshaft DAMPERS pulley is in good condition. If the hub/pulley
markings do not line up, the crankshaft pulley must be replaced.
- Peg the camshaft using the tool [2]
(The locating pegs [2] should slide in easily).
- If this is not the case, set the timing.
NOTE : Camshaft hubs (See pages 138 and 139).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY Engines : LFY - RFV - RFS RFV - RFS
SETTING THE VALVE TIMING.
- Peg the crankshaft using tool [3]. Refit :
- Peg the camshaft pulleys using - The pulley (5).
tool [2]. - The screw (4) (Tighten moderately).
- Lock the flywheel using the tool - The peg [3].
[6].
Remove :
Remove :
- The tool [6].
- The peg [3]. - The studs (8).
- The screw (4) (Brush the screw - Fit the tool [4].
thread). - Loosen the screws (10).
- The pulley (5). - Remove the tool [4].
- LThe lower cover (6). - Slacken the tensioner roller (7).
- Remove the belt (9).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY Engines : LFY - RFV - RFS RFV - RFS
Pretensioning the timing belt.
- Peg the crankshaft using the tool [3].
- Peg the camshaft pulleys using the tool [2].
NOTE : Ensure that the camshaft pulleys rotate freely on the hubs. Clean the
contact faces of the pulleys and hubs.
- Turn the camshaft pulleys in a clockwise direction to bring them to the end of the slots.
- Fit the belt (9)
- Fit the tool [1].
- Turn the roller (7) using the tool [5].
- Pre-tension to : (Pulleys slackened).
Engine LFY - RFV - RFS
New belt 55 SEEM units
- Tighten the screws of the roller (7) to 2 m.daN.
- Fit the tool [4].
- Tighten the screws (10) to 4 m.daN.
- Remove the tools.
- Rotate the crankshaft by six turns (Normal direction of rotation).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY Engines : LFY - RFV - RFS RFV - RFS
Tensioning the timing belt.
- Peg the crankshaft using the tool [3].
- Peg the camshaft pulleys using the tool [2].
NOTE : If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7),
and turn the camshafts using the screw (10).
- Fit the tool [4].
- Loosen the screws (10).
- Remove the tool [4].
- Loosen the tensioner roller (7).
- Fit the tool [1] to the belt.
- Turn the roller (7) using the tool [5].
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY Engines : LFY - RFV - RFS RFV - RFS
- Tension to : (Pulleys slackened).
Engine LFY - RFV - RFS
New belt 35 SEEM units
- Tighten the screw of the roller (7) to 2 m.daN.
- Fit the tool [4].
- Tighten the screws (10) to 7.5 m.daN.
- Remove the tools.
- Rotate the crankshaft by two turns (Normal direction of rotation).
- Check the pegging of the crankshaft/camshaft using tools [2] and [3].
NOTE : Tools [2] and [3] should slide in easily.
- Remove the tools.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : WJZ
TOOLS
- [1] HM screw : (-) 0 188 E
- [2] Locating peg Ø 6 mm : (-) 0 188 H
- [3] Flywheel locating peg : (-) 0 188 D ( ou 7014-T.J) Tool kit (-) 0 188.
- [4] Toothed sector for locking the flywheel : (-) 0 188 F
- [5] Belt retaining clip : (-) 0 188 K
- [6] Square drive for adjusting the tension : (-) 0 188 J
- [7] Belt tension measuring instrument : 4122-T
- [8] Toothed sector for locking the flywheel : 6016-T
Checking the valve timing
- Peg the flywheel using tool [3].
- Visually check that the offset between the camshaft and injection pump hub holes, and the corresponding peg-
ging holes do not exceed 1 mm.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : WJZ
SETTING THE VALVE TIMING
Peg :
- The camshaft hub (1), using tool [1].
- The injection pump pinion (2), using tool [2].
- The flywheel, using tool [3].
- Lock the flywheel, using tool [4].
- Refit the screw (3) (without tightening it). (Coat the threads with E6).
- Tighten the screw (3) to 4 m.daN and finish by carrying out an angular tightening
of 60°.
- Remove the tool [4].
- Retighten screws (4) and (5) by hand.
- Turn the pinions (6) and (2) so that they are at the end of their stops. (Clockwise
direction).
- Place the belt on the crankshaft and hold in place using tool [5].
- Fit the belt in the following order:
- Roller (7), pinion (2), pinion (6), pump (8) and roller (9).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : WJZ
SETTING THE VALVE TIMING (Continued)
NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction in
order to fit the belt.
The angular movement of the belt in relation to the pinions must not exceed 1/2 tooth.
- Fit the tool [7] to the belt strap at "a".
- Turn the roller (9) (anti-clockwise) using tool [6], to obtain:
106 ± 2 SEEM units.
- Check that pinions (6) and (2) are not at the end of their stops.
Otherwise, repeat the belt fitting procedure from the beginning.
Tighten:
- The roller (9) to 4.5 m.daN.
- The screws (4) and (5) to 2.5 m.daN.
- Remove the tools [7]. [5]. [1]. [2] and [3].
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ENGINE
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : WJZ
SETTING THE VALVE TIMING (Continued).
Rotate the crankshaft by 8 turns (direction of rotation).
Peg :
- The hub (1), using tool [1].
- The pinion (2), using tool [2].
- The flywheel, using the tool [3].
Loosen :
- The screws (4) and (5).
- The roller (9).
- Retighten screws (4) and (5) by hand.
- Fit the tool [7] to the belt strap at "a".
- Turn the roller (9) (anti-clockwise direction) using tool [6], to obtain : 42 ± 2 SEEM units.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : WJZ
SETTING THE VALVE TIMING (Continued)
Tighten :
- The roller (9) to 4.5 m.daN.
- The screws (4) and (5) to 2.5 m.daN.
- Remove the tool [7].
- Fit the tool [7] to the belt strap at "a".
- The tensioning value should be between 42 ± 2 SEEM units.
ESSENTIAL : If the value obtained is outside the set limits, repeat the tensioning
operation.
- Remove the tools [7]. [5]. [1]. [2] and [3].
- Rotate the crankshaft by 2 turns (direction of rotation).
- Check the valve timing.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : DHY
TOOLS
- Crankshaft locating peg : 7014 - T.J or 7014 - T.R
- Camshaft and injection pump locating peg : 7004 - T.G Tool kit 7004-T.
CHECKS
- Peg the crankshaft.
- Peg the pulleys (1) and (2) at "a" and «b».
SETTING THE VALVE TIMING.
- Peg the crankshaft.
- Peg the pulleys (1) at "a" and (2) at «b».
- Fit the belt in the following order :
Crankshaft pinion, guide roller (3), injection pump pulley (2), camshaft pulley (1), tensioner roller (5),
water pump (4).
- Remove the pegs.
- Free the tensioner roller (5) (nut (6) and screw (7)), retighten the screw (7).
- Rotate the crankshaft by 2 turns. Do not turn backwards.
- Loosen the tensioner roller (5), allow the tensioner to operate.
- Retighten the screw (7) and the nut (6). Tighten to 1.8 m.daN.
- Check the setting.
NOTE : The injection pump is removed without changing the valve timing. (immobilise the injection pump
pulley using the screws (8x125) at «b»).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY
Tools
[1] Belt tension measuring instrument : 4122-T
[2] Tension lever : (-).188.J2
[3] Engine flywheel peg : (-).0288.D
[4] Belt compression spring : (-).0188.K
[5] Camshaft pinion peg : (-).0188.M
[6] Engine flywheel lock : (-).0188.F
[7] Set of blocking plugs : (-).0188.T
[8] Crankshaft pulley extractor : (-).0188.P
Checking the setting of the valve timing.
Peg :
- The engine flywheel, tool [3].
- The camshaft, tool [5].
WARNING : Should it be impossible to peg the camshaft, check that the offset
between the camshaft pinion hole and the pegging hole is not more than 1 mm,
with the help of a mirror " a " and a Ø 7 mm screw.
IMPERATIVE : If pegging is impossible, restart the adjusting.
(See corresponding operation).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY
SETTING THE VALVE TIMING.
Peg :
- The engine flywheel, tool [3].
-The camshaft, tool [5].
Loosen :
- The three screws (9).
- The screw (7) of the tensioner roller (6).
Remove the timing belt.
Checks.
IMPERATIVE : Just before refitting, carry out the checks below :
Check that :
- The rollers (6), (11) and the water pump (10) turn freely (without play or tightness).
- There are no traces of oil (on camshaft or crankshaft).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY
SETTING THE VALVE TIMING (continued).
- Retighten screws (9) by hand.
- Turn the pinion (12) (clockwise) to the bottom of the
buttonhole.
- Refit the belt on the crankshaft, in the following
order, using the tool [4] to keep the belt tight at "a".
- Guide roller (11).
- Fuel high pressure pump pinion (13).
- Camshaft pinion (12).
- Water pump pinion (10).
- Tensioner roller (6).
NOTE : If needed, slightly turn the pinion (12) anti-
clockwise (offset should not be more than one tooth).
- Remove the tool [4].
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY
SETTING THE VALVE TIMING (continued).
- Position tool [1] on the belt at "b".
- Turn the roller (6) (anti-clockwise) using tool [2] to attain a tension of :
98 ± 2 SEEM units.
- Tighten screw (7) of the roller (6), tighten to 2.5 m.daN.
- Remove one screw (9) from the pinion (12).
(to check that the screws are not against the end of the buttonhole).
- Tighten the screws (9) to 2.m daN.
- Remove tools [1].[2].[3] and [5].
- Rotate the crankshaft 8 times (normal direction of rotation).
- Fit the tool [3].
- Loosen screws (9).
- Fit tool [5].
- Loosen screw (7) (to free the roller (6)).
- Fit tool [1].
- Turn the roller (6) (anti-clockwise), tool [2], to attain a tension of :
54 ± 2 SEEM units.
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY
SETTING THE VALVE TIMING (continued).
Tighten :
- The screw (7) of the roller (6) to 2.5 m.daN.
- The screw (9) to 2.m.daN.
- Remove the tool [1].
- Refit the tool [1].
- Tension value should be : 54 ± 3 SEEM units.
IMPERATIVE : If value is incorrect, restart the operation
- Remove tools [1].[3] and [5].
- Rotate the crankshaft 2 times (normal direction of rotation).
- Fit the tool [3].
WARNING : Should it be impossible to peg the camshaft, check that
the offset between the camshaft pinion hole and the pegging hole is
not more than 1 mm. In the case of an incorrect value, recommence
the operation.
- Remove the tool [3].
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ENGINE
XSARA SPECIAL FEATURES OF THE TIMING
Camshaft hub marking 11/97 LFY
Identification marks a - b
Inlet camshaft «a»
Exhaust camshaft «b»
Number in mark c
Inlet camshaft N° 1
Exhaust camshaft N° 2
Note : The identification marks are visible next to the pegging slot. Mark "c", bearing the
number, is engraved on the rear side of the hub (1).
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ENGINE
SPECIAL FEATURES OF THE TIMING XSARA
Camshaft hub marking LFY - RFV - RFS
Engines Hubs ‘‘a’’ marking ‘‘b’’ paint marking
Inlet C BLUE
LFY
Exhaust D BROWN
Inlet A GREEN
RFV
Exhaust B BLUE
Inlet
RFS B BLUE
Exhaust
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ENGINE
ALL TYPES VALVE CLEARANCE SETTINGS
POSSIBLE PROCEDURES
The valve clearances must be checked with the engine cold
For engines with 4 cylinders in a line (1-3-4-2 )
Rocking Fully open (Exhaust)
● Inlet Exhaust
Valves
Rocking Adjust fully Adjust
open
Petrol All Types
0.20 mm ± 0.05 0.40 mm ± 0.05 1● 1 4● 4 Exhaust 1 3 ● 4
(except 16V)
3● 3 2● 2 3 4 ● 2
4● 4 1● ● 4 2 ● 1
Petrol - 16V 1
Hydraulic adjustment Inlet
Diesel 2.0 HDi 2● 2 3● 3 2 1 ● 3
Diesel All
0.15 mm ± 0.08 0.30 mm ± 0.08 Engines without hydraulic
Types except 2.0 HDi
adjustment : the clearance (J)
should be checked opposite
the cam.
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ENGINE
CHECKING THE OIL PRESSURE ALL TYPES
Tools To be read with the Petrol and Diesel correspondence tables
Tool kit 4103-T TU all types XU all types EW XU all types
1.0 i 1.4 i 1.6i 1.6i 1.8 i 2.0 i 16 V
1.1 i 1.8 i
16 V 16 V
Engine type CDZ HDZ HFX KFX KFW NFZ NFT NFU NFX LFX LFY 6FZ RFN RFS RFV
Temperature (°C) 90° 80° 90° 80°
Pressure (Bars) 4 5.3 6 4 5.5 6.4
Rpm 4 000
TUD all types DW8 DW10TD
1.5 D 1.8 D 2.0 HDi
Engine type VJZ VJY VJX WJZ RHY
Temperature (°C) 90° 80°
Pressure (Bars) 4 4.5 4
Rpm 4 000
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ENGINE
ENGINE
ALL TYPES ENGINE OIL PRESSURE SWITCH
Location Tightening torque
Engine type Warning lamp goes out at : (Bars)
(m.daN)
1.0 i CDZ
HDZ
1.1 i
HFX
TU KFX
1.4 i
all types KFW
NFZ
1.6 i Above the oil filter 2.8
NFT
NFX 0.5
1.6 i 16v
NFU
1.8 i LFX
XU all types
LFY
1.8 i 16v
6FZ
EW
RFN
2.0 i 16v RFS
XU all types Close to the oil filter 3
RFV D6AP01MB D6AP01ND
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ENGINE
ENGINE OIL PRESSURE SWITCH ALL TYPES
Engine type Location Tightening torque
Warning lamp goes out at : (Bars)
(m.daN)
VJZ
TUD 1.5 D VJY
Above the oil filter 3.4
VJX 0.5
DW8 1.9 D WJZ
DW10 2.0 HDi RHY Close to the oil filter 2.8
D6AP01MB D6AP01ND
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ENGINE
ENGINE
ALL TYPES OIL FILTERS
To be read with the Petrol and Diesel correspondence tables
TU all types XU all types EW XU all types
1.6 1.8 i 2.0 i
1.0 i 1.1 i 1.4 i 1.6 i 1.8 i
16 V 16 V 16 V
CDZ HDZ HFX KFX KFW NFZ NFT NFU NFX LFX LFY 6FZ RFN RFS RFV
LS 867 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
PURFLUX
LS 304 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
TUD all types DW8 DW10
1.5 D 1.8 D 2.0 HDi
VJZ VJY VJX WJZ RHY
LS 867 ● ●
PURFLUX
LS 304 ● ● ● ● ●
Ø (mm) Height (mm)
LS 867
Specifications 76 89
LS 304
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ENGINE
FILLING AND BLEEDING THE COOLING CIRCUIT ALL TYPES
Filling and bleeding
- Fit the cylinder adaptor [2] 4222-T (Picasso) and the filling cylinder [1] 4520-T (all types).
- Use the coolant to ensure protection between - 15°C and - 37°C.
- Slowly fill the system.
NOTE : Keep the cylinder filled up (visible level).
- Close each bleed screw as soon as the coolant flows without air bubbles.
- Start the engine : Engine speed 1500 rpm.
- Maintain this speed until the third cooling cycle (cooling fans cut in and cut out).
- Stop the engine and allow it to cool down.
- Remove the filling cylinder [1] 4520-T (all types) and the cylinder adaptor [2] 4222-T (Picasso).
- Top up the system to the max. mark, with the engine cold.
- Refit the filler cap
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SAXO - All Types IDLING - ANTI-POLLUTION
Idling speed % Content
Emission (± 50 rpm)
Vehicle Engine type Make - Injection type
standard Auto. gbox : N CO CO2
Man.
gbox gear engaged
CDZ BOSCH MA3.1
INJECTION
1.0 i
CDY BOSCH MA3.1
1.1 i L3 BOSCH MA3.1
1.1 i HDZ BOSCH MA3.1(Petrol)/
Dual fuel BRC ECOGAS (LPG)
1.1 i HFX BOSCH M7.4.4. 850
L4
SAXO KFW SAGEM 2000 < 0.5 >9
1.4 i L3 M. MARELLI 1AP81 850
KFX
IF L4 BOSCH MP7.3
1.6 i (90 hp) NFZ L3 BOSCH MP5.2
1.6 i (100 hp) NFT L4 BOSCH M7.4.4.
L3 M. MARELLI 1AP41
1.6 i 16V NFX 800
L4 M. MARELLI 48P2
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IDLING - ANTI-POLLUTION XSARA - All Types
Idling speed % Content
Emission (± 50 rpm)
Vehicle Engine type Make - Injection type
standard Auto. gbox : N CO CO2
Man.
gbox gear engaged
INJECTION
1.4 i K'/L3 M. MARELLI 1AP40
SAGEM SL96 (Petrol)/
1.4 i
KFX L3 BRC FLYING INJECTION
Dual fuel
(LPG) 850
1.4 i IF L4 BOSCH MP7.3
1.6 i NFZ K'/L3 BOSCH MP5.2 800
XSARA < 0.5 >9
1.8 i LFX M. MARELLI 1AP20 800
1.8 i 16V SAGEM SL96
1.8 i 16V LFY L3 SAGEM SL 96 (Petrol)/
Dual fuel NECAM KOLTEC (LPG) 850
RFV BOSCH MP5.2
2.0 i 16V
RFS M. MARELLI 1AP10
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XSARA PICASSO - All Types IDLING - ANTI-POLLUTION
Idling speed % Content
Emission (± 50 rpm)
Vehicle Engine type Make - Injection type
standard Auto. gbox : N CO CO2
Man.
gbox gear engaged
1.6i
INJECTION
NFZ L3 BOSCH - MP7.2 850
(90 hp)
XSARA
< 0.5 > 0.9
PICASSO
1.8i 6FZ L4 SAGEM - S2000 700
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IDLING - ANTI-POLLUTION BERLINGO - All Types
Idling speed % Content
Emission (± 50 rpm)
Vehicle Engine type Make - Injection type
standard Auto. gbox : N CO CO2
Man.
gbox gear engaged
INJECTION
HDZ L3 / W3 BOSCH MA3.1
1.1 i
HFX L4 / W4 BOSCH M 7.4.4.
K'/L3
1.4 i M. MARELLI 1AP40 850
BERLINGO W3 < 0.5 >9
KFX
1.4 i L3 SAGEM SL96 /
Dual fuel BRC FLYING INJECTION
1.4 i KFW L4 / W4 SAGEM 2000
1.8 i LFX L3 / W3 M. MARELLI 1AP20 800
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SAXO - All Types PETROL INJECTION
SAXO
1.1 i
1.0 i 1.0 i 1.1 i 1.1 i
Dual fuel
Engine type CDZ CDY HDZ HFX KFW
INJECTION
Emission standard L3 L4
BOSCH BOSCH BOSCH MA3.1 BRC ECOGAS M. MARELLI SAGEM
Injection make and type
MA3.1 MA3.1 (Petrol) (LPG) M7.4.4 S2000
Fuel pressure (bars) 1 /
Overspeed cut-off (rpm) 6 420 6 420 6 510 6 000
Injection cut-in during /
1500 1500 1500 except 1st
deceleration (rpm)
Injector resistive value (ohms) 7 /
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Idling actuator: 11
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
150
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PETROL INJECTION SAXO - All Types
SAXO
1.4 i 1.6 i
AUTO. (90 hp) (100 hp) 16 V
Engine type KFX KFX NFZ NFT NFX NFX
INJECTION
Emission standard L3 IFL4 L3 L4 L3 L4
M. MARELLI BOSCH BOSCH BOSCH M. MARELLI M. MARELLI
Injection make and type
1AP81 MP7.3 MP5.2 M.7.4.4 1AP41 48P2
Fuel pressure (bars) 3.5 3.5 2.5 2.5
Overspeed cut-off (rpm) 6 400 6 440 6 314 7 300
Injection cut-in during exc. aircon: 1 426 1 300 at 2 500 1 300 at 2 400
1 500
deceleration (rpm) stationary: 4 550≈ except 1st (no cut-off with no throttle)
Injector resistive value (ohms) 16 14.5 3.5 14.5 14.5
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Stepper motor: 53
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
151
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XSARA - All Types PETROL INJECTION
XSARA
1.4 i
1.6 i
Dual fuel
Engine type KFX NFZ
INJECTION
Emission standard K'/L3 L3 IFL4 K'/L3
M. MARELLI SAGEM SL96 BRC FLYING BOSCH BOSCH
Injection make and type
1AP40 (petrol) INJECTION (LPG) MP7.3 MP5.2
Fuel pressure (bars) 3 / 3.5 2.5
Overspeed cut-off (rpm) 6 500 6 400 6 000 6 440 6 314
Injection cut-in during Depending on 1 300 at 2 500
1 500 at 1 800 / 1 500
deceleration (rpm) gear ratio except 1st
Injector resistive value (ohms) 14.5 16 / 12 14.5
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Stepper motor: 53
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
152
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PETROL INJECTION XSARA
XSARA
1.6i 16V 2.0I 16V
Engine type NFU RFN
INJECTION
Emission standard L3 L4
BOSCH M. MARELLI
Injection make and type
M7.4.4. MM 48.P2
Fuel pressure (bars) 3 1 3
Overspeed cut-off (rpm) 6 530 7 300
Injection cut-in during
1 200 1 350
deceleration (rpm)
Injector resistive value (ohms) 14.5 16
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Stepper motor: 53
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
153
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XSARA - All Types PETROL INJECTION
XSARA
1.8 i 1.8 i 16 V
16 V Dual fuel
Engine type LFX LFY LFY
INJECTION
Emission standard L3 L3 L3
M. MARELLI SAGEM SL96 NECAM KOLTEC
Injection make and type SAGEM SL96
1AP20 (petrol) (LPG)
Fuel pressure (bars) 3 3 3 /
Overspeed cut-off (rpm) 6 400 6 500 6 500 6 300
Injection cut-in during 1 500
1 400 1 500 1 300 at 1 500
deceleration (rpm)
Injector resistive value (ohms) 14.5 16 16 /
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Stepper motor: 53
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
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PETROL INJECTION XSARA - BERLINGO - All Types
XSARA BERLINGO
2.0 i
1.1 i 1.4 i
16 V
Engine type RFV RFS HDZ HFX KFX
INJECTION
Emission standard L3 L3 L3 K'/L3
BOSCH M. MARELLI BOSCH BOSCH M. MARELLI
Injection make and type
MP5.2 1AP10 MA3.1 M7.4.4 1AP40
Fuel pressure (bars) 3 3 1 / 3
Overspeed cut-off (rpm) 6 530 7 300 6 510 6 000 6 500
Injection cut-in during 1 500 Depending
1 200 1 350 /
deceleration (rpm) except 1st on gear ratio
Injector resistive value (ohms) 14.5 16 7 / 12
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Stepper motor: 53 Stepper motor: 53
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
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BERLINGO - All Types PETROL INJECTION
BERLINGO
1.4 i
1.4 i 1.8 i
(Dual fuel )
Engine type KFX KFW KFX LFX
INJECTION
Emission standard W3 L4 /W4 L3 K'/L3
M. MARELLI SAGEM SAGEM BRC FLYING M. MARELLI
Injection make and type
1AP40 S2000 SL96 INJECTION 1AP20
Fuel pressure (bars) 3 3.5 3.5 / 3
Overspeed cut-off (rpm) 6 500 6 440 6 440 6 000 6400
Injection cut-in during 1 500 at 1800
deceleration (rpm)
1 500 / 1 400
Injector resistive value (ohms) 12 12 12 / 14.5
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Stepper motor: 53
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
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PETROL INJECTION XSARA PICASSO - All Types
XSARA PICASSO
1.8i
1.6 i
16 V
Engine type NFZ 6FZ
INJECTION
Emission standard L3 L4
BOSCH SAGEM
Injection make and type
MP7.2 S2000
Fuel pressure (bars) 3.5 1 3.5
Overspeed cut-off (rpm) 6 300 6 500
Injection cut-in during
1 150 1 300
deceleration (rpm)
Injector resistive value (ohms) 14.5 12.2
Engine coolant temperature
sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
Idling actuator or stepper
motor resistive value (ohms)
Stepper motor: 53
Air temperature sensor
resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
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ALL TYPES EMISSION STANDARDS
STANDARD APPLICATIONS NOTES CHARACTERISTICS
PSA
E.E.C Engines Vehicle Applicable
A-S RP
Private vehicles: Brussels directive 83/351
INJECTION
> 2 litres ➞ 06/89 ➞ except special derogations
• new cyl. < 2 litres ➞ 06/92 for certain private vehicles
• existing cyl. < 2 litres ➞ 12/92 cyl. > 2 litres
ECE K 15.04 Petrol Utility vehicles: ➞ 10/89 ➞ Utility vehicle limits
R 15.04 K’ 15.04 Diesel All Types = private vehicle limits
increased by 25 % With oxygen sensor,
imminent ➞ For private vehicles without catalytic converter
and utility vehicles
in major export
Private vehicles: Brussels directive 88/76
ECE > 2 litres " Luxembourg Accords "
R 15.05 W vp 15.05 Petrol • new models 01/10/88 ➞ ➞ Replaced by 89/458
• existing models 01/10/89 ➞ + 91/441
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EMISSION STANDARDS ALL TYPES
STANDARD APPLICATIONS NOTES CHARACTERISTICS
PSA
E.E.C Engines Vehicle Applicable
A-S RP
Utility vehicles: Brussels directives 88/76
INJECTION
All Types and 88/436
• new models 01/10/88 ➞
➞ Utility vehicle
• existing models 01/10/89 ➞
ECE limits = private vehicle
15.05 Petrol ➞ 10/94
R 15.05 W vu
Diesel limits of Brussels
directive 88/436
7 classes of limits
byvehicle weight
Private vehicles: Current ➞ Adoption of U.S. standard With oxygen sensor
Petrol • certain non-EEC and catalytic converter
US 83 Z US 83
Diesel
European countries for petrol vehicles
• certain Export countries
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ALL TYPES EMISSION STANDARDS
STANDARD APPLICATIONS NOTES CHARACTERISTICS
PSA
E.E.C Engines Vehicle Applicable
A-S RP
Private vehicles: Current ➞ Adoption of U.S. standard With catalytic
INJECTION
• certain non-EEC converter and EGR
US 87 Y US 87 Diesel
European countries
• certain Export countries
Petrol Private vehicles: Current ➞ Adoption of U.S. standard
US 93 Y2 US 93
Diesel • certain Export countries
Utility vehicles: Current ➞ Adoption of U.S. standard
US 84 Petrol • certain non-EEC standard for light utility vehicles
X1 US 84
LDT Diesel European countries
• certain Export countries
Utility vehicles: Current ➞ Adoption of U.S. standard
US 87 Petrol • certain non-EEC standard for light utility vehicles
X2 US 87
LDT Diesel European countries
• certain Export countries
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EMISSION STANDARDS ALL TYPES
STANDARD APPLICATIONS NOTES CHARACTERISTICS
PSA
E.E.C Engines Vehicle Applicable
A-S RP
Private vehicles: Current ➞ Adoption of U.S. standard
INJECTION
US 90 Petrol • certain non-EEC standard for light utility vehicles
LDT X3 US 90
Diesel European countries
• certain Export countries
Private vehicles: Brussels directive 89/458
EURO 1 < 1.4 litres 07/92 ➞
CEE Petrol
L1 19.5
• new models ➞ 01/07/93 ➞ Possible alternative to
(EURO Diesel
93)
• existing models ➞ 31/12/94 emission standard L
from 1992 to 1994
Private vehicles: With oxygen sensor and
EURO 1 All Types catalytic converter for
CEE Petrol • new models 07/92 ➞ EU Brussels Directive 93/59 petrol vehicles.
L
(EURO 19.5 Diesel • existing models 01/93 ➞ (91/441) With catalytic converter
93) • new models ➞ 01/96 and EGR for diesel
• existing models ➞ 01/97 vehicles.
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ALL TYPES EMISSION STANDARDS
STANDARD APPLICATIONS NOTES CHARACTERISTICS
PSA
E.E.C Engines Vehicle Applicable
A-S RP
Utility vehicles:
INJECTION
< 3.5 tonnes
• new models 01/10/93 ➞ Brussels Directive 93/59
EURO 1 • existing models 01/10/9 ➞
Class 1 : ➞ 3 classes depending on With oxygen sensor and
CEE Petrol catalytic converter for
W2 • new models ➞ 01/97 vehicle weight :
(EURO W2 Diesel
Class 1 < 1250 kg petrol vehicles
93) • existing models ➞ 10/97 Class 2 : 1250/1700 kg
Class 2/3 : Class 3 > 1700 kg
• new models ➞ 01/98
• existing models ➞ 10/98
Private vehicles: With oxygen sensor and
EURO 2 Brussels Directive 94/12
< 6 seats and reinforced catalytic converter
CEE Petrol
L3 < 2.5 tonnes for petrol vehicles. With
(EURO 95 Diesel ➞ EURO 93 standard made
96) • new models 01/96 ➞ stricter catalytic converter and
• existing models 01/97 ➞ EGR for diesel vehicles.
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EMISSION STANDARDS ALL TYPES
STANDARD APPLICATIONS NOTES CHARACTERISTICS
PSA
E.E.C Engines Vehicle Applicable
A-S RP
Utility vehicles:
INJECTION
< 3.5 tonnes Brussels Directive 96/69 With oxygen sensor and
EURO 2 Class 1 : reinforced catalytic converter
Petrol • new models 01/97 ➞
➞ 3 classes depending on
CEE Diesel for petrol vehicles. With
W3 vehicle weight :
(EURO 95 • existing models 10/97 ➞
96) Gas Class 1 < 1250 kg catalytic converter and
Class 2/3 : Class 2 : 1250/1700 kg EGR for diesel vehicles.
• new models 01/98 ➞ Class 3 : 1700 kg
• existing models 10/98 ➞
Private vehicles: With 2 oxygen sensors
All Types and catalytic converter for
Brussels Directive 98/69
EURO 3 • new models 01/2000 ➞ petrol vehicles.
Petrol
CEE • existing models 01/2001 ➞
L4 Diesel ➞ EURO 2 standard (L3) With catalytic converter
(EURO 2000
Gas made stricter
2000) and EGR for diesel
➞ Fiscal incentives
vehicles.With EOBD
on-board diagnosis.
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ALL TYPES EMISSION STANDARDS
STANDARD APPLICATIONS NOTES CHARACTERISTICS
PSA
E.E.C Engines Vehicle Applicable
A-S RP
Utility vehicles: Brussels Directive 98/69 With 2 oxygen sensors
INJECTION
< 3.5 tonnes ➞ EURO 2 standard (L3) and catalytic converter for
Class 1 : ➞ 01/2000 made stricter petrol vehicles.
EURO 3 Petrol • new models ➞ 01/2001 ➞ Fiscal incentives With catalytic converter
Diesel ➞ 3 classes depending on and EGR for diesel
(EURO W3 • existing models
Gas vehicle weight : vehicles.
2000) Class 2/3 : ➞ 01/2001
Class 1 < 1305 kg
• nouveaux modèles ➞ 01/2002 Class 2 : 1305/1760 kg With EOBD on-board
• existing models Class 3 : 1760 kg diagnosis.
Private vehicles: Brussels Directive 98/69
With 2 oxygen sensors
All Types
and catalytic converter for
EURO 4 IF / L5 • new models 01/96 ➞ ➞ EURO 3 standard (L4)
Petrol petrol vehicles. With
made stricter
• existing models 01/97 ➞ EOBD on-board diagnosis.
➞ Fiscal incentives
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ANTI-POLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPES
All Types Petrol CO Corrected (In %) All Types Diesel (m -1)
Conditions : At idle, engine warm.
# 01/96 Features :
Less than 4.5 % for vehicles registered before 10/86.
INJECTION
Less than 3.5 % for vehicles registered after 10/86. Xantia, MMDCM injection on 1.6i (BFZ) engine, 1.8i (LFZ) engine and
2.0i (RFX) engine.Should the check reveal excessive CO, make sure
With catalytic converter that the ECU channel 25 is not connected to earth in error.
Greater than 2.0i 89 M.Y.
All Types 93 M.Y. (See Info-rapid N° 77)
CO less than 0.5 % at idle speed.
CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm (*). 01/96 #
(*) Except : Atmospheric engine.
TU5 JP : 2200 rpm ± 100.
XU5JP : 1500 rpm or 3100 rpm (± 100). Less than 2.5 m-1
XU7JP : 1500 rpm or 3100 rpm (± 100).
NOTE : On XU5JP and XU7JP engines at 1500 rpm, the check should Turbocharged engine.
be carried out with main beams, rear heated screen and cabin ventilation
switched on and with the front wheels on maximum lock (if the vhicle Less than 3.0 m-1
has power-assisted steering).
Lambda Probe value 0.97 at 1.03.
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ALL TYPES SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM
ESSENTIAL : Special precautions should be taken when dealing with gas powered systems
INJECTION
SAFETY REQUIREMENTS.
Only personnel who have been specially trained to work with petrol/LPG DUAL FUEL vehicles are authorised to carry out repairs to
the DUAL FUEL system
- Ensure that these qualified personnel are provided with acrylic-free overalls
(risk of static electricity)
In the event of a major gas leak
- Isolate the vehicle in the open air, away from any buildings
- Call the emergency services (police and fire brigade) should the situation get out of hand
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SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM ALL TYPES
PRECAUTIONS TO BE TAKEN BEFORE CARRYING OUT ANY REPAIR WORK
Any work on a gas powered vehicle must be carried out in a venti- Before removing the fuel tank or working on the gas circuit located
lated area. downstream of the safety electrovalve (on the gauge valve), perform
Disconnect the battery negative terminal. the following operations :
INJECTION
Ensure the vehicle is connected to earth. - Close the safety electrovalve.
- Switch the engine to use gas.
Ensure the vehicle is kept away from the following hazards : - Wait for the engine to stop due to lack of fuel.
- Sparks.
- Flames. After each operation, check that the circuit is sealed using one of
- Slow combustion (lit cigarette). the following systems :
Drain the fuel tank using "flare" type material (following the ins- Electronic detector .
tructions for this material) before performing one of the following - Soapy water.
operations : - Any other leak detection product.
- Remove the gauge valve. Remove the fuel tank when the vehicle is to be subject to high
- Working on the fuel tank. temperatures (above 50oC) (spray booth).
Do not clean the engine compartment with a high pressure device
and do not use detergents .
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ALL TYPES SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
INJECTION
B1HP0Q4P B1CV0Q5P
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SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM ALL TYPES
(1) Fuel tank. (6) Injectors and valves.
- Capacity : 70 litres. - location : in the engine compartment, under the air manifold.
- Max. pressure : during tests / in operation : 30 bars / 20 bars. (7) Pressure sensor.
- Max. operating temperature : 50°C.
INJECTION
- supply voltage : 5 volts.
- Location : in the boot. - location : on the evaporator control valve support.
(2) Fuel gauge (8) Temperature sensor 15°C.
- supply voltage : 12 volts. - location : on the control valve reheating circuit.
- resistance : 0 to 15 ohms empty, 280 to 315 ohms full.
(9) LPG filter.
- location : on the gauge valve;
- Type : paper.
(3) LPG gauge valve. - replacement intervals: every 60,000 Km.
- location : on the fuel tank. - location : on the evaporator control valve inlet union.
(4) Safety electrovalve. (10) Supply electrovalve.
- supply voltage : 12 volts. - supply voltage : 12 volts.
- power : 8W - power : 8W.
.- resistance : 18 ohms. - resistance : 18 ohms.
- location : on the gauge valve - location : on the evaporator control valve inlet union.
(5) Filler orifice with safety valve.
- location : on the rear right wing.
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ALL TYPES SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
(11) Evaporator control valve. Setting pressure - 2nd stage.
- make : NECAM.
- type : MEGA. - Setting pressure for a new evaporator control valve :
• - 970 ± 10 mb.
INJECTION
ESSENTIAL :
- Setting pressure for a used evaporator control valve :
Before checking and setting the pressure, it is essential that you
read through and follow closely BROCHURE REF : 0332. • - 960 ± 10 mb.
(12) Stepper motor.
Setting pressure - 1st stage.
- location : on the distributor.
- Setting pressure for a new evaporator control valve :
• 1450 ± 50 mb.
(13) Distributor.
- Setting pressure for a used evaporator control valve : - location : on the evaporator control valve support.
• 1400 ± 50 mb.
(14) Distributor electrovalve.
- supply voltage : 12 volts.
- resistance : 25 ohms.
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PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO
Engine : RHY
Cleaning.
- The use of high pressure cleaners is prohibited
.- Do not use compressed air.
INJECTION
Fuel supply circuit.
- Required fuel : diesel.
WARNING : Do not use other fuels.
Electric circuit.
- Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.
High pressure fuel pump.
Do not separate the following components from the high pressure fuel pump (5) :
- High pressure fuel pump third piston deactivator (3) (no replacement parts).
- High pressure fuel regulateur (4) (no replacement parts).
- Sealing ring (1) (no replacement parts).
- High pressure outlet connector (3) (will cause a malfunction).
B1HP12CC
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XSARA - XSARA PICASSO PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engine : RHY
High pressure fuel injection common rail.
- Do not separate the connectors (7) from the common injection rail (6).
- (malfunction).
Diesel injectors.
INJECTION
WARNING : Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel injector carrier (9) :
- Diesel injector (8) (no replacement parts).
- Electromagnetic element (11) (destruction).
- Do not alter the position of the nut (10) (malfunction).
- Do not separate the connector (12) from a diesel injector.
B1HP12DC - It is forbidden to clean the carbon deposits from the diesel injector nozzle
- Identification : Injector carrier.
- There are two types of diesel injector carrier classed according to fuel flow.
Identification by engraving or paint mark
Injector carrier Engraving Paint mark Location
Class 1 1 Blue Sur la partie supérieure du
Bobinage vers l'orifice de
Class 2 2 Green retour de carburant
Identification markings: IMPERATIVE: When replacing a diesel
- "a": Supplier identification. injector carrier, order a component of
- "b": PSA identification number. the same class.
B1HP12EC - "c": Class identification. (See repair manual). B1HP16PC
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SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO
Engine : RHY
SAFETY REQUIREMENTS
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations :
- Competent health authorities.
INJECTION
- Accident prevention.
- Environmental protection.
WARNING : Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.
Safety requirements.
IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect
the requirements below :
- No smoking in proximity to the high pressure circuit when work is being carried out.
- Avoid working close to flame or sparks.
Engine running :
- Do not work on the high pressure fuel circuit.
- Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries.
- Do not place your hand close to any leak in the high pressure fuel circuit.
After the engine has stopped, wait 30 seconds before any intervention.
NOTE : This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.
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XSARA - XSARA PICASSO SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engine : RHY
CLEANLINESS REQUIREMENTS.
Preliminary operations
INJECTION
IMPERATIVE : The technician should wear clean overalls.
Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding
procedures).
- Fuel filter.
- High pressure fuel pump.
- High pressure fuel injection common rail.
- High pressure fuel pipes
- Diesel injector carriers.
IMPERATIVE : After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities.
Work area.
- The work area must be clean and free of clutter.
- Components being worked on must be protected from dust contamination.
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CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA - XSARA PICASSO
Engine : RHY
TOOLS
[1] Ø 10 mm low pressure connector : 4215-T
[2] Ø 8 mm low pressure connector : 4218-T
INJECTION
[3] Pressure gauge for testing boost pressure : 4073-T Tool kit 4073-T
Connect the tool [1] between the booster pump and the fuel filter (white mark at "a"
on the fuel supply pipe).
Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel
pump and the fuel filter (green mark at "b" on the fuel return pipe).
WARNING : Any check of pressure downstream of the fuel filter is PROHIBITED.
Checks on pressure : static.
- Switch on ignition
For 3 seconds (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar.
B1BP1TWD
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XSARA - XSARA PICASSO CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engine : RHY (continued)
Checks on pressure : dynamic.
Engine running, at idle (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.7 ± 0.4 Bar.
Abnormal functioning
INJECTION
Fuel supply pressure Fuel return pressure Checks
Between 3 and 3.5 Bar 0.7 ± 0.2 Bar Check the condition of the diesel filter
More than 3.5 Bar Less than 0.7 Bar Check the low pressure regulator incorporated in
the filter (locked shut) : replace.
More than 3.5 Bar More than 0.7 Bar Check the fuel return circuit (pipe pinched or trapped.......).
Check the fuel suppy circuit :
Between 0.8 and 1.5 Bar Less than 0.7 Bar - Booster pump (low pressure), piping.
Impossible to start the engine : Check : diesel injector return flow. (Table below)
Fuel supply pressure less than 0.8 Bar :
- Check the low pressure regulator incorporated in the filter (locked open) Uncouple the diesel injector return pipe.
- Check the high pressure pump distribution valve (locked shut)
Check : Observe :
The flow should be drop by drop Diesel injector functioning correctly
Excessive fuel return Diesel injector locked shut.
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CHECKS : AIR SUPPLY CIRCUIT XSARA - XSARA PICASSO
Engine : RHY
TOOLS
[1] Manual vacuum pump : FACOMM DA 16.
IMPERATIVE : Respect the safety and cleanliness requirements.
Vacuum pump.
INJECTION
- Connect the tool [1] on the vacuum pump (1).
- Start the engine.
- Pressure should be 0.8 bar at 780 rpm.
Boost pressure regulator electrovalve.
- Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure
regulator.
Compare readings with the values in the table below.
Engine speed (rpm) Pressure (Bar)
780 0.6
4000 0.25
Pressure regulator valve.
- Connect the tool [1] on the valve (3).
- Appy a pressure of 0.5 bar to activate the rod "a" :
- Rod "a" should be moved 12 mm.
B1HP12FD
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XSARA - XSARA PICASSO CHECKS : TURBO PRESSURE
Engine : RHZ
Tools.
[1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T
[2] Sleeve for checking boost pressure : 4185-T
[3] Adaptor sleeve : 4229-T
INJECTION
Checks.
IMPERATIVE : respect the following checking requirements : Engine at running
temperature. Vehicle in running order at full load.
Preparation.
- Remove the collar fixing (3).
- Insert the tool [2] connected with tool [3], between the pipe (1) and the duct (2).
- Position tool [1] in the vehicle.
- Connect the sleeve [2] to the tool [1] with its tube "a".
Procedure.
- Start the engine.
- Engage first gear and start the engine.
- Engage the gears up to third gear.
- Decelerate to 1000rpm.
- Accelerate hard, and check the pressure : 0.6 ± 0.05 Bar (1500 rpm).
- Accelerate freely in kick-down, (changing from fourth to third gear).
- Check the pressure : 0.95 ± 0.05 Bar (between 2500 and 3500 rpm).
- Remove the tools, reposition the pipe (1) and refit the collar (3).
B1HP12JD
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CHECKS : TURBO PRESSURE XSARA - XSARA PICASSO
Engines : RHY
TOOLS.
[1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T
[2] Sleeve for checking boost pressure : 4185-T
INJECTION
Checks.
IMPERATIVE : respect the following checking requirements : Engine at running tempe-
rature. Vehicle running at full load.
Preparation.
- Remove the collar (3) and the sleeve.
- Insert the tool [2] between the pipe (1) and the duct (2).
- Position tool [1] in the vehicle.
- Connect the pressure gauge [1] to the tool [2] with its tube "a" long enough for the gauge to
be positioned inside the vehicle.
Procedure.
- Start the engine.
- Engage first gear and start the engine.
- Engage the gears up to third gear.
- Decelerate to 2000 rpm.
- Gradually accelerate.
- Check the pressure : 0.95 ± 0.05 Bar.
- Remove the tools, refit the collars (3) and the sleeve.
B1BP1ZXD
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XSARA - XSARA PICASSO CHECKS : EXHAUST GASES RECYCLING CIRCUIT
Engine : RHY
TOOLS
[1] Manual vacuum pump : FACOMM DA 16.
IMPERATIVE : Respect the safety and cleanliness requirements.
INJECTION
EGR valve
- Connect the tool [1] to the capsule union (1).
- Apply, several times in succession, a vacuum of approx. 0.6 bar to activate the rod "a".
- In abrupt reaction to the vacuum, the valve should close on its seating with a clicking noise.
Exhaust gas reycling (EGR) electrovalve.
- Check, not under load, between the electrovalve (2) and the EGR valve (1).
- Connect the tool [1] between the electrovalve (2) and the capsule (1).
- Compare readings with the values in the table below.
Engine speed (rpm) Pressure (Bar)
780 0.5
2500 0
B1HP12GD
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SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP SAXO - XSARA
PUMP -TYPE - REFERENCE
Emission standards L3
Equipment Transponder
DPC
INJECTION
SAXO
TUD 5 VJZ R 8444 B/
XSARA
662 C
DWLP 12
DW 8 WJZ R8448 B
371 B
XSARA
XUD 110
XUD 9TD DHY R8445B/
081 A
181
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SAXO - XSARA SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
Static timing Dynamic Reference Adjustments (rpm) Max. speed
Injector
Pump
Engine Initial advance timing Injector Colour
Type needle lift Fast Anti- Unladen Laden
type Compression checking Injector holder code Idling
Reference pressure idling stall rpm rpm
Time (at idle) + injector (Bar)
(cylinder N° 4)
INJECTION
VJZ DPC 14 ° before RDN 1600
LDC 135 1000 800 5450
VJY TDC 12SDC PINK + 15 mm
010R01B +5 - 0 ± 100 ± 25 ± 125
VJX R 8444 B/ * (Not adjustable) 6849 shim
DWLP 12 RDNO 1500
LCR 135.5 950 875 875 5350
WJZ Crankshaft SDC +3 mm
6736001 ±5 ± 25 ± 25 ± 25 ± 125
R 8448 B/ * TDC 6903 shim
hole.
Value «X»
engraved on the 1500 800
XUD 110 WHITE 144.5 950 5150
pump. 6734 4600
DHY + + 4 mm +0 -50
6872D 303D ± 2.5 ± 50 ± 125 ± 80
R 8445 B/ * GREEN shim (1)
( ) See table on page : 181
*
182
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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP SAXO - XSARA
Engine : VJZ - VJY - VJX
Tools
- Flywheel locating peg : 4507-T.A
INJECTION
- Mounting plate locating peg : 4527-T.S1 Tool kit 4507-T
- Camshaft peg : 4527-T.S2
Checks
- Peg the flywheel.
- Visually check the pegging of the camshaft and pump pulleys, or check using the
tools 4527-T.S1 and 4527-T.S2.
Setting the injection pump
- Peg :
- The flywheel.
- The camshaft pulley.
- Fit the pump and tighten to 2.5 m.daN.
- Peg the pump mounting plate.
- Fit the pump drive pinion together with the timing belt. Tighten to 2.5 m.daN.
B1HP0YAC
183
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XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Engine : WJZ
Evolution of the checking of the setting of the LUCAS diesel injection pump
Old assembly. NEW ASSEMBLY : RPO 7910 #
INJECTION
Diesel injection pump with hole for Diesel injection pump without a hole
checking the setting for checking the setting.
The setting of the diesel injection pump is The setting of the diesel injection pump
done with the aid of the following tools : is done with the aid of a peg at "c".
- A peg placed at "a".
- A peg and a dial gauge placed in the
checking hole at "b".
See method on following pages.
B1HP1A4C B1HP1A5C
184
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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA
Engine : WJZ
Tools.
[1] Flywheel locating peg : 7014-T.J.
[2] H M8 screw : (-).0188.E. Tool kit C.0188
INJECTION
[3] Injection pump setting peg Ø 6 mm : (-).0188.H
After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner :
Remove :
- The screws (6), (7), (9), (10) and (12).
- The upper casing (8).
- The intermediate casing (11).
WARNING : Refit the screw (6) equipped with a washer. (Thickness 5 mm).
- Turn the front RH wheel to turn the engine. (Normal direction of rotation).
- Bring the camshaft and injection pump pulleys to their setting point.
- Position the flywheel peg, using tool [1]. (From above the vehicle).
- Turn the engine until the peg [1] engages in the flywheel.
B1EP12NC B1BP1S9C
185
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XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Engine : WJZ (continued)
Peg :
- The camshaft hub, using tool [2].
- The injection pump hub, using tool [3].
INJECTION
Impossible to peg the camshaft.
Reset the valve timing (See pages 127 to 131).
Possible to peg the camshaft, but not the injection pump.
Carry out the following operations:
- Loosen the screws of the injection pump hub.
- Turn the injection pump hub.
- Insert the peg [3] into the setting hole.
- Tighten the screws of the injection pump hub. Tighten to 2.3 ± 0.2 m.daN.
ESSENTIAL : If setting the diesel injection pump proves impossible, reset the valve
timing (See pages 127 to 131).
Remove:
- The tools [1]. [2] and [3].
- The screw (6) and the washer.
Reassemble the components.
B1EP12WD B1BP1S9C
186
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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA
Engines : DHY
TOOLS
Rep : 4093-T
1 Peg - Flywheel locating peg : 7014-T.J.Tool kit 7004-T
2 Bracket
INJECTION
- Bracket and peg : 4093-T Tool kit 4123-T
3 Dial gauge
4 Flat end
5 Relay lever
CHECKING THE PUMP
- Peg engaged: The dial gauge should read "X" ± 0.03 engraved on the pump.
- If not, check the timing again.
SETTING THE PUMP
- Insert the peg (1) into the pump
- The peg must be against the guide tube "a". (If not, turn the engine backwards).
- Fit the tool 4093-T.
- Set the dial gauge to "0".
- When the dial gauge starts to move, it signifies that the piston is nearing TDC.
- Peg the flywheel.
- Slowly turn the pump toward the engine until measurement "X" can be seen.
B1HPOL6C B1HPON9C
("X" = Value engraved on each pump).
187
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SAXO - XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
Engines : VJZ - VJY - VJX
ADJUSTING THE FAST IDLE
INJECTION
Engine cold.
- Ensure that the lever (1) is up against its stop to the right.
- If not, adjust the tension of the cable (3) using the cable clamp (2). (Tighten to 0.5 m.daN).
- Finish tensioning using the sleeve tensioner (4).
- Tighten the lock nuts to 1.7 m.daN.
Engine hot.
- Ensure that the cable (3) is slack.
- Check the operation of the thermostatic sensor on the coolant outlet housing.
- There should be a minimum 6 mm cable travel between "engine cold" and "engine hot".
- If this is not the case, replace the thermostatic sensor. Tighten to 2.5 m.daN.
B1HP08YD B1HP0HUC
188
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ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS SAXO - XSARA
Engines : VJZ - VJY - VJX (continued)
ADJUSTING THE ACCELERATOR CONTROL.
INJECTION
Engine stopped.
- Fully depress the accelerator pedal.
- Check that the lever (5) is against its stop (6), otherwise, alter the position of the clip (7)
(Accelerator cable tension).
- Ensure that in the idle position the lever (5) is against the stop (8).
Adjusting the anti-stall (Residual output).
- Insert a 1.5 mm thick shim between the lever (5) and the residual output adjustment
screw (8).
- Adjust the residual output adjustment screw (8) to obtain an engine speed of 1600 ± 100 rpm
- Remove the 1.5 mm thick shim.
Idling speed.
Adjust the idle speed adjustment screw (9) to obtain a speed of 800 ± 25 rpm.
B1HP090D
189
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SAXO - XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
Engines : VJZ - VJY - VJX (continued)
Checking the engine deceleration.
- Move the throttle lever (5) to obtain an engine speed of 3000 rpm.
INJECTION
- Release the throttle lever (5).
- The deceleration should be between 2 and 3 seconds.
Deceleration Deceleration
too fast too slow
Engine has a Engine speed is greater
Problem encountered tendency to stall than the idle speed
Step to be taken Tighten the screw (8) Slacken the screw (8)
by a quarter turn by a quarter turn
NOTE : In each case, check the idle speed for any necessary adjustments.
ESSENTIAL : Check the operation of the manually-operated "STOP" control (10).
B1HP090D
190
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ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS XSARA
Engine : WJZ
Adjusting the fast idle.
Engine cold.
- Ensure that the lever (2) is up against its stop to the right.
INJECTION
- If not, adjust the tension of the cable (3) using the cable clamp (1).
- Finish tensioning using the sleeve tensioner (4).
Engine hot.
- Check that the cable (3) is in tension.
Checking the thermostatic sensor.
- There should be a minimum 6 mm cable travel between a cold and a hot engine.
Adjusting the accelerator control.
Prior conditions.
- Engine hot (cooling fan is engaged twice).
Checking the accelerator cable tension.
- Fully depress the accelerator pedal.
- Check that the lever (6) is against its stop (5) otherwise, alter the position of the pin.
- If not, adjust the position of the accelerator cable tensioning retaining pin.
- Ensure that in the idle position the lever (6) is against the stop (7).
B1HP0K9C
191
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XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
Engine : WJZ (continued)
Adjusting the anti-stall (residual output).
- Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7).
- Push the stop lever (8).
INJECTION
- Insert a 3 mm diameter peg (9) in the lever (2).
- Adjust the engine speed to 1500 rpm ± 100 using the stop screw (7).
- Remove the shim (10) and the peg (9).
Adjusting the idle speed.
- Adjust the speed using the idle adjustment screw (11).
- Idling speed : 825 ± 25 rpm.
Checking the engine deceleration.
- Move the throttle lever (6) to obtain an engine speed of 3000 rpm.
- Release the throttle lever (6).
- The deceleration should be between 2.5 and 3.5 seconds.
- The drop should be approximately 50 rpm in relation to the idle speed.
- Deceleration too fast, (the engine has a tendency to stall) slacken the screw (7) by a quarter turn.
- Deceleration too slow, (engine speed is greater than the idle speed) tighten screw (7) by a quarter turn.
NOTE : In each case, check the idle speed for any necessary adjustments.
B1HP0K9C B1HP0KAC
192
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ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS XSARA
Engine : RHY
Engine cold :
- Check the fast idle speed.
- Ensure that the lever (9) is against its stop by pushing it in the direction of the arrow (‘). If
not, adjust with the cable clamp (8), and then the sleeve tensioner (4).
INJECTION
Fast idle :
- Refer to the specifications on page : 182
Engine hot :
- Ensure that cable (7) is slack.
Engine stopped:
- Fully depress the accelerator pedal, check that the lever (5) is against its stop (3).
Residual output (Anti-stall))
- Insert a 4 mm thick shim at (a) between the lever (5) and the screw (6). - Set the engine
speed to 1500 ± 100 rpm using the stop screw (6).
Idling speed :
- 800 +0 rpm using the screw (2) (Air conditioning + 50 rpm).
-50
Engine deceleration : from 3000 rpm to ‘‘0’’.
- Deceleration too fast (tendency to stall) : Loosen (6) by a 1/4 turn.
- Deceleration too slow : tighten (6) by a 1/4 turn.
B1HPOYDD
193
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SAXO - XSARA FITTING DELPHI DIESEL INJECTORS
Engines : VJZ - VJY – VJX - DHY
Fitting an injector [1] Tool to remove/refit injectors 7007-T
[2] 7008-T.A Tool kit 4123-T
The copper seal (1) and the
fire seal washer (3) are to be
INJECTION
replaced each time they are
removed.
NOTE : Fitting parts of diffe-
rent makes is PROHIBITED.
WARNING :
Ensure that the fire seal
washer (3) is fitted the right
way round.
Tighten the injector holder
on
the cylinder head to :
VJZ
7 m.daN
(3) Tighten lightly to prevent any distortion.
All Types Tighten to 1 m.daN + 20° or 6 m.daN.
9 m.daN
B1HPOYEC B1HPOYFC B1HPOYGC
194
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FITTING DELPHI DIESEL INJECTORS XSARA
Engine : WJZ
[1] Tool to remove/refit injectors (2) 7007-T
Fitting an injector
[2] 7008-T.A Tool kit 4123-T
The copper seal (1) and the
fire seal washer (3) are to be
INJECTION
replaced each time they are
removed.
NOTE : Fitting parts of diffe-
rent makes is PROHIBITED.
WARNING : Ensure that the fire
seal washer (3) is fitted the right
way round.
Tighten the injector holder
on the cylinder head to :
9 m.daN
(3) Tighten lightly to prevent any distortion.
B1DP158C B1HP12VC B1HP0YGC
195
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SAXO - XSARA - XSARA PICASSO BOSCH INJECTION PUMP SPECIFICATIONS
PUMP -TYPE - REFERENCE
Emission standards L3/L4
Equipment Transponder
SAXO VE
INJECTION
XSARA VJZ VJY 8 F 25000
TUD 5 R 611/5
SAXO VJX 539
DHY XUD 213
XUD 9TD
R 445/3
XSARA
DW 10 RHY CP1 (*)
(*) = The fuel high pressure pump is driven by the timing belt.
196
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BOSCH INJECTION PUMP SPECIFICATIONS SAXO - XSARA - XSARA PICASSO
Static timing Dynamic Reference Injector Adjustments (rpm) Max. speed
Pump Colour
Engine (1) Initial advance timing Injector needle
Type Fast Anti- Unladen Laden
type Compression checking Injector holder lift Idling
Reference code idling stall rpm rpm
Time (at idle) + injector pressure
(cylinder N° 4) (Bar)
INJECTION
DNOSD 835
VJZ VE Setting 299 A KCE 1000 ± 40 800 5450
by GREEN
30S8 ± 100 + 1 mm ± 25 ± 125
VJY
8F 2500 / * pegging DNOSD
120 shim
3026
±5
Pump
KCA 800 5450 5000
VJX 539 0,60 ± 0,1 mm 299 No
20S106 ± 100 ± 160 ± 160
after BDC
Pump KCA +
XUD 213 175 ± 50 875 5350 4500
DHY 0,66 mm 11°± 1° 299 17S42 BLUE 3 mm
VE R 445 / * +5 -0 (2) ± 25 ± 125 ± 80
after BDC (218) shim
96255
RHY CP1 Non-adjustable 42580
(1) = Engine : TDC peg hole - (2) = Auto gearbox or air con. + 50 rpm - Auto gearbox and air con. + 100 rpm (*) = See table page : 196
197
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SAXO - XSARA CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP
Engine : VJZ -VJY - VJX
TOOLS
- Flywheel locating peg : 4507-T.A
- Mounting plate locating peg : 4507-T.S1 Tool kit 4507-T
INJECTION
- Camshaft peg : 4507-T.S2
CHECKS
- Peg the flywheel.
- Visually check the pegging of the camshaft and injection pump pulleys, or check using
the tools 4527-T.S1 and 4527-T.S2.
SETTING THE INJECTION PUMP.
- Peg :
• The flywheel.
• The camshaft pulley.
- Fit the pump and tighten to 2 m.daN.
- Peg the pump mounting plate.
- Fit the pump drive pinion together with the timing belt. Tighten to 2 m.daN.
B1HP0YAC
198
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CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP XSARA
Engine : DHY
TOOLS
- Flywheel locating peg : 7017-T.R. Tool kit 7004-T
- Ring spanner : 4132-T.
- Crescent spanner FACOM 57 : 11 X 13
INJECTION
- Dial gauge : 3089-T.H.
- Dial gauge bracket : 7010.T. Tool kit 4123-T.
- 31 mm lever : 5003-T.D.
SETTING THE INJECTION PUMP.
- Tilt the pump in the retarded direction (away from the engine).
- Fit the timing tool.
- Turn the engine (direction of engine rotation) until the peg engages in the flywheel.
- Ensure that the pump pinion can be pegged (if not, rotate the crankshaft by 1 turn).
- Remove the tool 7017-T.R
- Find the BDC position of the pump (by turning the crankshaft backwards) and set
the dial gauge to ‘‘0’’.
- Turn the crankshaft (direction of engine rotation) until the locating peg 7017-T.R engages.
- Turn the pump, in the advance direction (towards the engine) until the dial gauge shows
(See the table on pages : 197).
NOTE : The dial gauge needle must not move when tightening.
B1HP0YKD
199
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XSARA CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP
Engine : DHY
TOOLS
Flywheel setting peg : 7017-T.R Tool kit 7004-T
INJECTION
Checking the injection pump.
- Remove the tool 7017-T.R.
- Rotate the crankshaft (direction of rotation).
- Peg the flywheel.
- In this position, the dial gauge should show the value ‘‘X’’ (See the table on page : 197).
- The value ‘‘X’’ corresponds to the travel of the pump piston in relation to the BDC.
- Remove the tool.
B1HP0NQC B1HP0NPC
200
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CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP SAXO - XSARA
Engine : VJZ - VJY - VJX
ADJUSTING THE FAST IDLE SPEED.
- Bring the lever (3) into contact with the screw (2).
INJECTION
- Use the screw (2) to obtain the fast idle speed : 1100 ± 100 rpm.
Engine cold :
- Ensure that the lever (3) is up against the screw stop (2).
- If not, slightly tension the cable (4) using the cable clamp (1).
- Finish tensioning with the sheath tensioner (5).
Engine hot :
- Ensure that the cable (4) is slack.
- Check the operation of the thermostatic sensor on the coolant outlet housing : there should be a minimum
6 mm cable travel between a cold and a hot engine.
- If not, replace the thermostatic sensor. Tighten to 2.5 m.daN.
B1HP0HQC B1HP0HUC
201
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SAXO - XSARA CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP
Engine : VJZ - VJY - VJX (continued)
ADJUSTING THE ACCELERATOR CONTROL.
- Fully depress the accelerator pedal.
INJECTION
- Check that the lever (10) is against the stop screw (6). If not, modify the
position of the spring clip (7).
- Check that, at idle, the lever (10) is against its stop (9).
Preliminary conditions :
- Engine hot (The cooling fan is engaged twice).
- Fast idle control released.
ADJUSTING THE IDLE SPEED.
- Slacken the screw (9) by a few turns until it no longer touches the lever (10).
- Adjust the idling speed using the screw (8).
B1HP0HSD
202
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CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP SAXO - XSARA
Engine : VJZ - VJY - VJX (continued)
ANTI-STALL ADJUSTMENT
- Insert a 1 mm shim [1] between the throttle lever (10) and the residual
INJECTION
output adjustment screw (9).
- Turn the residual output adjustment screw (9) to obtain an engine speed of :
835 ± 40 rpm.
- Remove the shim [1].
CHECKING THE ENGINE DECELERATION.E
- Move the throttle lever (10) to obtain an engine speed of 3000 rpm.
- Release the throttle lever (10).
- The deceleration should be between 2 and 3 seconds.
ESSENTIAL : Check the operation of the manually-operated ‘‘STOP’’
control (11).
B1HP0HRD
203
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SAXO - XSARA FITTING BOSCH INJECTORS
Engines : VJZ - VJY - VJX - DHY
[1] Tool to remove/refit injectors (2) 7007-T
Fitting an injector
[2] 7008-T Tool kit 4123-T
The copper seal (1) and the
fire seal washer (2) are to be
INJECTION
replaced each time they are
removed.
NOTE : Fitting parts of diffe-
rent makes is PROHIBITED.
WARNING : Ensure that the fire
seal washer (2) is fitted the right
way round.
Tighten the injector holder
on the cylinder head to :
VJZ
7 m.daN
All Types
(3) Tighten lightly to avoid distortion.
9 m.daN Tighten to 7 m.daN.
B1HP0YNC B1HP0YPC B1HP0YGC
204
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PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO
Engine : RHY
Evolution : Classification of diesel injector carriers
Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection
16/11/98 # duct diameters (flow of diesel fuel).
INJECTION
Identification.
The injector carriers have an engraving or paint mark on the upper part of the coil, close to the diesel fuel
return aperture :
Mark 1 = BLUE paint mark = Injector class 1.
Mark 2 = GREEN paint mark = Injector class 2.
Identification marking:
a : Supplier identification.
b : PSA identification no.
c : Identification of class.
After Sales operations.
ESSENTIAL : When changing a diesel injector carrier, order a component of the same class.
# 15/11/98 (RPO No.) (injector carrier without marking), always order a class 2 injector carrier.
B1HP16PC
205
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ALL TYPES SPARKING PLUGS
Vehicles – Models Electrode Tightening
Engine type BOSCH CHAMPION EYQUEM
gap setting torque
1.0i CDZ
1.1i HDZ
IGNITION
SAXO 1.4i KFX FR7DE RC8YCL RFC58 LZ 0.9 mm
1.6i NFZ
1.6i 16v NFX
1.4i KFX
1.6i NFZ
FR7DE RC8YCL RFC58 LZ 2.5 mdaN
1.8i LFX
XSARA 0.9 mm
1.8i 16v LFY
2.0i 16v RFS RFN 52 LZ
2.0i 16v RFV FR7DE RC8YCL RFC58 LZ
1.1i HDZ
BERLINGO 1.4i KFX FR7DE RC8YCL RFC58 LZ 0.9 mm
1.8i LFX
206
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SPEEDOMETER ALL TYPES
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.
This decree stipulates :
-The speed indicated by a speedometer must never be lower than the actual vehicle speed.
- Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship :
VR < VL < 1.10 VR + 4 Km/h
Example : For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.
The speed indicated by the speedometer may be influenced by :
DRIVESHAFTS
GEARBOX
CLUTCH
- The speedometer.
- The tyres fitted to the vehicle.
- The final drive ratio.
- The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle. (See information note N° 78-85 TT of 19 October 1978).
NOTE : Before replacing the speedometer, check the conformity of the following points :
- The tyres fitted to the vehicle.
- The gearbox final drive ratio.
- The speedometer drive ratio.
207
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ALL TYPES CLUTCH SPECIFICATIONS
1.0 i 1.1 i 1.4 i 1.6 i
Engine type CDZ HDZ HFX KFX KFW NFZ
Gearbox MA/4 - MA/5
Make VALEO
Mechanism/Type 180 CP 3400 180CPO 3400 200 CPR 3800
200X(D95)
Clutch disc 181 XJ (E73) 11 R 10 X 180 XJF 73 C
11A12X
Ext./Int. lining Ø 180/127 200/137
DRIVESHAFTS
GEARBOX
CLUTCH
Disc lining type F 408 F 408 F 808
208
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CLUTCH SPECIFICATIONS ALL TYPES
1.6i 1.6i 16V 1.5 D
Engine type NFT NFX NFU VJZ VJY VJX
Gearbox MA/5
Make VALEO LUK
Mechanism/Type 200 CPR 3800 200 CPX 3850 180 P 3000
Clutch disc 200 X (D 95) 11 AX 12 X 200 XSL 73 180 D
Ext./Int. lining Ø 200/137 180/135
DRIVESHAFTS
Disc lining type F 410 F 808 F 410
GEARBOX
CLUTCH
209
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ALL TYPES CLUTCH SPECIFICATIONS
1.8i 1.8i 16V 2.0i 16V 1.9D 1.9TD 2.0 HDi
Engine type LFX LFY 6FZ RFN RFS RFV WJZ DHY RHY
Gearbox BE4/5
Make VALEO LUK VALEO LUK
215 DT
Mechanism/Type 200 CP 4250 230 DNG 4700 215 DT 5250 200 P 3700 230 P 4700
5250
Clutch disc 215 F 215 FM
200 B (D73) 33AX 230 DNG 4700 215 F D95 200 228
(D 93) 22 BX (95) 11 AX
DRIVESHAFTS
GEARBOX
Ext./Int. lining Ø 200/137 228/155 215/147 200/134 215/147 228
CLUTCH
Disc lining type F 408 F 808 F408 F 202 F 408
210
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CLUTCH : CHECKS AND ADJUSTMENTS SAXO - XSARA
Mechanically operated push-action clutch (adjustable)
SAXO Adjustable CDZ-HDZ-HFX-KFX-KFW-NFZ-NFT-NFX-VJZ-VJY-VJX
Engines Gearbox MA/5
XSARA Non-adjustable* VJZ-KFX-NFZ
(*) See page 214)
ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching
successively a minimum of 20 times.
Checks
NOTE : Adjustable steering wheels should be put into the low position
- Record the measurement ‘‘X’’ between positions L1, pedal at rest, and L2, pedal fully depressed.
DRIVESHAFTS
GEARBOX
- Measurement ‘‘X’’ should be : (Pedal travel).
CLUTCH
SAXO
135 ± 5 mm
Adjustments.
- If the measurement is incorrect, adjust the clutch pedal travel "X".
- Loosen the lock nuts (1).
- To adjust the travel to conform with the measurements indicated above, either loosen or tighten the nut (2)
(Tighten the nut to increase the travel, and loosen it to decrease the travel.)
- Tighten the lock nut (1).
B2BP023C B2BP00GC
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XSARA CLUTCH : CHECKS AND ADJUSTMENTS
Push-action clutch with automatic adjustment (non-adjustable) (*)
Engines LFX - LFY - WJZ Gearboxes BE3/5 – BE4/5
Refitting the clutch cable.
- Set the pedal to the high position (contact at A).
- Attach the cable end-piece to the pedal.
- Refit a new clip (3) to the pedal.
- Fit the end-piece (4) to the bulkhead (G6 grease).
- Clip the end-piece (5) to the gearbox.
- Refit the cable to the lever (1).
- Depress the clutch cable several times to set the assembly
DRIVESHAFTS
in place.
GEARBOX
CLUTCH
- Check that the end-piece (4) is properly fitted to the bulkhead.
- Check the operation of the automatic adjusting device.
1) - Pull the lever (in direction F), the lever must move
when pulled by hand.
2) - Press the clutch pedal very lightly and repeat the same
operation. The lever should not move back.
(*) See pages 215-216).
B2BP03CD
212
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CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO
Pull-action clutch with automatic adjustment (non-adjustable) (*)
Engines RFS - RFV - RHY Gearbox BE3/5
Refitting the clutch cable.
- Set the pedal to the high position (contact at A).
- Attach the cable end-piece to the pedal.
- Refit a new clip (3) to the pedal.
- Fit the end-piece (4) to the bulkhead (G6 grease).
- Clip the end-piece (5) to the gearbox.
- Refit the cable to the lever (1).
DRIVESHAFTS
- Depress the clutch cable several times to set the assembly
GEARBOX
CLUTCH
in place.
- Check that the end-piece (4) is properly fitted to the bulkhead.
- Check the operation of the automatic adjusting device.
1) - Pull the lever (in direction F), the lever must move
when pulled by hand.
2) - Press the clutch pedal very lightly and repeat the same
operation. The lever should not move back.
(*) See pages 215-216).
B2BP03DD
213
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XSARA - XSARA PICASSO CLUTCH : CHECKS AND ADJUSTMENTS
Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)
Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY
WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the
pedal position must be adjusted. This position is obtained by the angular displacement of the stop
supports "a" and "b".
Procedure
- Loosen the nut (6) and the screw (7).
- Using a lever, raise the stop support (8) to its highest position.
- In this position, there must be a substantial free play in the pedal.
DRIVESHAFTS
- Lower the support until there is a free play of 2 ± 1 mm.
GEARBOX
CLUTCH
- Tighten the screw (7) and the nut (6).
- Check that the outer cable slides freely (at rest, the pedal is against its upper stop "A", the outer cable
length should be variable).
Characteristics
- The automatic adjusting device requires no manual adjustment.
- Pedal travel remains constant for all models 145 ± 5 mm.
- Automatic adjustment is achieved by modifying the curvature of the outer cable.
- Take extra care with the routing of the outer cable, and do not add any supplementary fixing points.
B2BP03EC
214
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CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO
Engines : LFX - LFY - RFS - RFV - WJZ - RHY
DRIVESHAFTS
GEARBOX
CLUTCH
B2BP02SC
NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable.
DESCRIPTION
1 - Metallic cable, crimped on both ends. 5 - Tensioning spring ensuring the maximum length of the cable sleeve.
2 - Outer cable or telescopic duct. 6 - Wear take-up device.
3 - Outer cable stop, bulkhead side (fixed point on the bodyshell). 7 - Hooking yoke.
4 - Outer cable stop, gearbox side (fixed point on the gearbox).
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XSARA - XSARA PICASSO CLUTCH : CHECKS AND ADJUSTMENTS
Engines : LFX - LFY - RFS - RFV - WJZ - RHY (continued)
DRIVESHAFTS
B2BP03QD
GEARBOX
CLUTCH
Operation Clutch disengagement phase Engagement / adjustment phase
For the adjusting device to operate correctly, it As soon as the pedal is applied, the attaching The pedal returns to rest on its upper
is necessary that : end-piece (4) leaves the sleeve (1) which stop.Attaching end-piece (4) pushes sleeve (1)
The pedal is at rest (against its upper stop) The moves back. The rollers, pushed by spring (5) which frees the rollers.
locking sleeve (1) is slightly compressed, the jam the system. The cable behaves like a Outer cable (3), kept extended by the spring (6)
rollers (2) are free, the outer cable (3) length conventional cable. becomes :
may vary. - Shorter if the clutch disc is worn.
- Longer if the outer cable has been compressed.
NOTE : The pedal gear has a non-adjustable assisting device.
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GEARBOX AND TYRE SPECIFICATIONS SAXO - All Types
Petrol
1.4i
1.0i 1.1i
Automatic
Engine type CDZ HDZ HFX KFX KFW
Tyres-Rolling circumference 155/70 R 13 – 1.67 m
Gearbox type MA/4 – MA/5 MB3 MA/4 – MA/5
20 CF 12
Gearbox ident. plate 20 CF 03 20 CF 02 20 CF 12
29/08/200 ➞ 03/05/200 ➞ 20 CF 02 312 03/05/200 ➞
29/08/200 ➞
Reduction box torque 14X60 17x64 17x56 17x64
Speedometer ratio 19x17 21x19 19x17
DRIVESHAFTS
GEARBOX
Petrol Diesel
CLUTCH
1.6i 1.6i 16V 1.5D
Engine type NFZ NFT NFX VJZ VJY VJX
Tyres-Rolling circumference 165/65 R14 – 1.725m 185/55 R14 1.7 m 165/65 R14 – 1.725 m
Gearbox type MA/5 MA/5
20 CD 05 20 CN 03 20 CN 03 20 CF 02
Gearbox ident. plate
29/08/200 ➞ 03/05/200 ➞ 29/08/20 ➞ 29/08/200 ➞
Reduction box torque 17x64 17x61 16x63 17x64
Speedometer ratio 19x17 19x17
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XSARA # 09/2000 GEARBOX AND TYRE SPECIFICATIONS
Petrol
1.4i 1.6i 1.8i 1.8i 16V
Automatic
Engine type KFX KFW NFZ LFX LFY
Tyres-Rolling circumference 185/65 R14 – 1.815 m
Gearbox type MA/5 AL4 BE3/5
20 CE 42
Gearbox ident. plate 20 CE 42 20 CD 29 20 TP 22 20 TB 91 20 TB 62
03/05/2000 ➞
Reduction box torque 14x60 16x65 21x73 19x70 19x75
Speedometer ratio 22x17 21x18 24x21 22x19
DRIVESHAFTS
Petrol Diesel
GEARBOX
CLUTCH
2.0i 16V 1.5D 1.9D 1.9TD 2.0 HDi
Automatic
Engine type RFV RFS VJZ WJZ DHY RHY
Tyres-Rolling circumference 195/55 R15 – 1.815 m 185/65 R14 – 1.820 m
Gearbox type BE3/5 4 HP 20 BE3/5 MA/5 BE3/5
20 TB 92 20 TB 51
Gearbox ident. plate 20 TB 39 20 GZ 9F 20 CE 46 20 TB 38 20 TB 59
20 TB 93 1.815 m
Reduction box torque 19x72 17x65 19x72 14x60 19x75 19x77 19x70
Speedometer ratio 22x19 21x18 22x19
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GEARBOX AND TYRE SPECIFICATIONS XSARA 09/2000 #
Petrol
1.4i 1.6i 16V 2.0i 16V
Automatic Automatic
Engine type KFW NFU RFN RFS
Tyres-Rolling circumference 195/55 R15 – 1.815 m
Gearbox type MA/5 AL4 BE4/5 AL4 BE4/5
Gearbox ident. plate 20 CF 13 (1) 20 CN 28 (2) 20 TP 49 20 DL 40 20 TP 47 20 TE 47
Reduction box torque 16 x 65 21 x 73 19 x 72 23 x 73 14 x 62
Speedometer ratio 21 x 18 24 x 21 22 x 19 24 x 21 22 x 19
DRIVESHAFTS
Diesel
GEARBOX
CLUTCH
1.9D 2.0 HDi
Engine type WJZ RHY
Tyres-Rolling circumference 195/55 R15 – 1.815 m
Gearbox type BE4/5
Gearbox ident. plate 20 DL 41 20 DL 42
Reduction box torque 19x75 19x70
Speedometer ratio 22x19
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XSARA PICASSO GEARBOX AND TYRE SPECIFICATIONS
Petrol Diesel
1.6i 1.8i 16 V 2.0 HDi
Engine type NFZ 6FZ RHY
Tyres-Rolling circumference 185/65 R15 – 1.895 m
Gearbox type BE4/5
Gearbox ident. plate 20 DL 66 20 DL 68 20 DL 64
Reduction box torque 15x64 19x77 19x72
Speedometer ratio 22x18
DRIVESHAFTS
GEARBOX
CLUTCH
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MA/5 GEARBOX SAXO - XSARA
Engines : CDZ - HDZ - HFX - KFW - KFX - NFZ - NFT - NFU - NFX - VJZ - VJY - VJX
Vent hole
DRIVESHAFTS
GEARBOX
CLUTCH
Filler screw Drain screw
B2CP34HP B2CP20FC B2CP20GC
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SAXO - XSARA MA/5 GEARBOX CONTROLS
Engines : CDZ - HDZ - HFX - KFW - KFX - NFZ - NFT - NFU - NFX - VJZ - VJY - VJX
1 - Gear lever.
2 - Gear control rod.
3 - Gear control rod.
A = 11.5 mm.
DRIVESHAFTS
4 - Gear selection rod.
GEARBOX
B = 9.5 mm.
CLUTCH
5 - Gear selection rod.
C = 3 mm.
6 - Knuckle joint
7 - Fixed point on the gearbox.
B2CP16SP B2CP16TC
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BE3/5 GEARBOX XSARA - XSARA PICASSO
Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY
DRIVESHAFTS
GEARBOX
CLUTCH
Filler screw Drain screw Vent hole
B2CP34JP B2CP20HC B2CP20JC
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XSARA - XSARA PICASSO BE3/5 GEARBOX CONTROLS
Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY
(1) - Gear lever.
(2) - Gear control rod.
(3) - Gear engagement rod.
(4) - Gear selection rod.
(5) - Torque rod.
DRIVESHAFTS
GEARBOX
CLUTCH
(6) - Gear engagement ball-joint.
(7) - Fixed point on the gearbox.
NOTE : The gear change mechanism is
not adjustable.
B2CP197D
224
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BE4/5 GEARBOX SPECIFICATIONS XSARA - XSARA PICASSO
ENGINES : NFZ - 6FZ - RFN - RFS - WJZ - RHY
DRIVESHAFTS
GEARBOX
CLUTCH
(a) = Marking zone (Sequence and serial no.).
(b) = Location of identification label.
B2CP3BNC B2CP3BPD
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XSARA - XSARA PICASSO BE4/5 GEARBOX SPECIFICATIONS
Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY
Description
(1) Primary shaft. (14) 1st / 2nd gear synchroniser
(2) Clutch bearing guide. (15) Driven gear (1st gear).
(3) Gearbox casing. (16) Secondary shaft.
(4) Clutch housing. (17) Differential gear.
(5) Reverse idle. (18) Satellite gears.
(6) Drive gear (3rd gear). (19) Planet gears.
(7) 3rd /4th gear synchroniser (20) Differential housing.
DRIVESHAFTS
GEARBOX
(8) Drive gear (4th gear). (21) Speedometer drive.
CLUTCH
(9) Drive gear (5th gear). (22) Extension.
(10) 5th gear synchroniser.
(11) Driven gear (5th gear).
"d" Adjusting shims : 0.7 to 2.4 mm
(12) Driven gear (3rd / 4th gear )
(0.10 mm and increasing by 0.10 mm).
(13) Driven gear (2nd gear).
"c" Adjusting shims: 1.4 to 1.6 mm
(0.10 mm and increasing by 0.10 mm).
B2CP3BQP
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BE4/5 GEARBOX SAXO - XSARA - XSARA PICASSO
Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY
Tightening torques
Ref. Description Number of screws m.daN
1 End guide 3 1,2 ± 0,1
2 Clutch housing 13 1,3 ± 0,1
3 Primary shaft nut 1 7,2 ± 0,7
4 Secondary shaft nut 1 6,5 ± 0,7
5 Yoke holding screw 2 1,5 ± 0,1
DRIVESHAFTS
6 Differential gearwheel screw 2 6,5 ± 0,7
GEARBOX
CLUTCH
B2CP3BSP Reverse gear contact 1 2,5 ± 0,3
7 Differential housing 4 5 ± 0,5
8 Breather pipe 1 1,7 ± 0,2
9 Rear housing cover screw 7 1,2 ± 0,1
10 Top-up plug 1 2,2 ± 0,2
11 Differential housing screw 4 1,2 ± 0,1
B2CP3BTD 12 Drain plug screw. 1 3,5 ± 0,4
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SAXO - XSARA - XSARA PICASSO BE4/5 GEARBOX CONTROLS
Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY
(1) Gear control lever.
(2) Gear engagement control cable (*).
(3) Gear selection control cable (*).
(4) Gear selection ball-joint Ø 10 mm.
DRIVESHAFTS
GEARBOX
(5) Gear engagement ball-joint Ø 10 mm.
CLUTCH
(6) Flexible insulating grommet through the bulkhead.
(*) = These two cables cannot be separated.
B2CP3BWD
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BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS SAXO - XSARA - XSARA PICASSO
Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY
Principles of adjusting the gear controls.
WARNING : Cables should be adjusted each time the gearbox,
gear controls or power unit are removed.
Principles.
WARNING : Do not use any tool to unclip the
Lock the gear lever in neutral position,using tool: ball-joints.
9607-T.
To unlock the ball-joint, press at the centre "a",
DRIVESHAFTS
Place the gearbox in neutral. then pull the ball-joint upwards.
GEARBOX
CLUTCH
Couple the cables on the lever. NOTE : Changing an individual ball-joint is possible
as long as the locking key is removed.
Fit the ball-joints on the gearbox lever.
Unclip at "b", using two small screwdrivers.
Lock the cable lengths with the ball-joint locking
keys.
B2CP3BXC B2CP3BYC
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SAXO - XSARA - XSARA PICASSO BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS
Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY
Adjusting the gear controls.
TOOLS.
[1] ] Tool for positioning the gear lever : 9607-T.
ADJUSTMENTS. CHECKS.
WARNING : Cables should be adjusted each
- Remove the tool [1].
time the gearbox, gear controls or power unit
- Check that all the gears engage without "tightness".
are removed.
- Check that the gear lever moves identically forwards
Inside the vehicle. and backwards and to right and left. If it does not,
DRIVESHAFTS
- Remove the trim under the gear lever. repeat the adjustment.
GEARBOX
CLUTCH
- Lock the gear lever in neutral position,using tool [1].
- Refit the trim under the gear lever.
Under the bonnet. - Refit the air filter assembly.
- Remove the air filter assembly.
- Unlock the ball-joint keys at "a".
- Place the gear selection and control levers neutral.
- Lock the cable lengths with the ball-joint locking
keys
B2CP3C6C B2CP3C0C
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MB3 AUTOMATIC GEARBOX SAXO
Engine : KFX
Tightening torques m.daN.
- Gearbox to engine fixing 3.5
- Converter to engine fixing 2.5
- Converter closing plate fixing
M8 1.6
M10 2.6
- Electrical bracket fixing 6.5
DRIVESHAFTS
- Flexible mounting to gearbox fixing 8.5
GEARBOX
CLUTCH
- Speedometer drive 1
- Heat exchanger fixing 5
NOTE : When fitting a new automatic gearbox, it is
ESSENTIAL that the heat exchanger and the oil be
replaced.
B2CP14ZP
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SAXO RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX)
Engine : KFX
PRECAUTIONS TO BE TAKEN
Towing REMOVING - REFITTING. (Automatic gearbox).
The front of the vehicle must be raised in order to be towed.If the front WARNING : Never place the gearbox on its lower casing (risk of
of the vehicle cannot be raised : deforming the tray and damaging the hydraulic valve block).
- Add an extra 2 litres of oil to the automatic gearbox.
- Do not exceed 30 kph over a distance of 50 km. Driveshafts.
- Gear lever in position "N". ESSENTIAL : When moving the left driveshaft, ensure it remains
WARNING : Do not forget to remove the extra oil. horizontal (risk of losing the tri-axe joint needles).
DRIVESHAFTS
GEARBOX
Driving. Initialising procedure.
CLUTCH
Never drive with the ignition switched off. The gearbox should be initialised in the following cases :
Never push the vehicle to try to start it (impossible with an automatic - Replacement of the ECU.
gearbox). - Clearing of faults.
NOTE : The automatic gearbox is only lubricated when the engine is - Replacement of the potentiometer.
running. - Replacement or adjustment of the accelerator cable.
Wait until the vehicle is completely stationary before engaging the - Incorrect initialisation.
gear lever in position "P". NOTE : The initialisation procedure should be checked using a
diagnostic tool.
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RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX) SAXO
Engine : KFX
PRE-REPAIR PROCEDURE
Oil quality
If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the
oil will overheat and become contaminated with impurities : the oil is said to be "burnt".
This is characterised by a black colour and the presence of an unpleasant smell.
ESSENTIAL : The gearbox must be replaced.
Oil level (prior conditions)
DRIVESHAFTS
- Oil hot (80°C min.).
GEARBOX
CLUTCH
- Foot on the brake, change through all the gears.
- Vehicle on a level surface.
- Selection lever in position "P".
- Engine running.
The level should be between the min. markings "A" and "B" on the dipstick.
ESSENTIAL : In no case should the oil level exceed the marking "B".
Top up the automatic gearbox oil level (if necessary).
B2CP16WC
233
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SAXO RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX)
Engine : KFX
PRE-REPAIR PROCEDURE (continued)
Negative pressure circuit. Absence of fault codes
- Check the negative pressure circuit. Measure the parameters.
- Carry out the necessary repairs. Anomalies present:
- YES : Carry out the necessary repairs.
Checks using the diagnostic tool. - NO : Check (adjust the negative pressure capsule).
Preliminary checks : ESSENTIAL : Initialise the ECU
DRIVESHAFTS
- The adjustment of the gear selection control. Perform a road tes
GEARBOX
CLUTCH
- The adjustment of the accelerator cable.
Carry out the necessary operations Fault codes present
Carry out the necessary repairs.
Reading the fault codes Clear the fault codes.
Read the fault codes. ESSENTIAL : Initialise the ECU
Perform a road test.
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SPECIAL FEATURES : MB3 AUTOMATIC GEARBOX SAXO
Engine : KFX
Hydraulic valve block.
Refitting.
WARNING : On refitting the strainer, ensure that the bracket (6) runs under the
washer of the screw (7).
- Refit the strainer without tightening the screws.
- Observe the following tightening sequence :
- Screws 1,2,3,4 and 5 to 0.9 m.daN.
DRIVESHAFTS
GEARBOX
CLUTCH
ESSENTIAL : Respect the position of the magnets in the lower casing. Clean
the casing before placing the smooth side of the magnet against the sheet
metal.
Fitting the casing.
WARNING : The fixing brackets (8) of the lower casing have a fitting direction
(small side = lower casing side).
Tightening torque 0.6 m.daN.
B2CP34PC B2CP13TC B2CP34QC
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SAXO MB3 AUTOMATIC GEARBOX CONTROLS
Engine : KFX
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP352D
236
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MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS SAXO
Selection control Adjusting the selection control
WARNING: No part must be forced ESSENTIAL : Put the gearbox side
while performing these operations control in the 1st imposed position;
(careful removal). the 2 markings "a" must be aligned.
Removing the gear lever knob.
- Remove the screws (1).
- Lift the lever knob (2) by about 10 mm. - Fit the ball joint (1).
- Turn backwards by 1/4 turn, and - Fit the lug (2).
raise by approximately 7 mm.
- Press and hold down the locking
button (3). - Lock the outer cable stop by 1/4 turn
(in the direction of the arrow).
DRIVESHAFTS
GEARBOX
- Check that the painted markings "b"
CLUTCH
- Turn forwards by 1/4 turn, remove the gear lever knob (2). are aligned.
Refitting the gear lever knob
- Press and hold down the locking button (3).
- Fit the knob (2) on the lever until it touches its stop (in the direction
shown in the diagram).
- Release the locking button (3).
- Turn forwards by 1/4 turn.
- Refit the screws (1).
ESSENTIAL : Check the passage of all the gears, otherwise adjust
the selection control.
B2CP18YC B2CP18WC B2CP18XC
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XSARA AL 4 AUTOMATIC GEARBOX
Engines : NFZ - NFU - RFN
WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil
which cannot be mixed with any other oil.
The gearbox is lubricated for life.
(a) Part reference.
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP30ZD
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RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA
Engines : NFZ - NFU - RFN
PRECAUTIONS TO BE TAKEN
Towing REMOVING - REFITTING. (Automatic gearbox).
The front of the vehicle must be raised in order to be towed.If the front
of the vehicle cannot be raised :
WARNING : Never place the gearbox on its lower casing (risk of
IMPERATIVE : - Put gear lever in position "N". deforming the tray and damaging the hydraulic valve block).
- Do not add any oil. Never use the connections as handles for raising, turning, holding or
- Do not exceed 50 kph over a distance of 50 km. pushing the gearbox
Driving. ESSENTIAL :
DRIVESHAFTS
Never drive with the ignition switched off.
- Fit the converter retaining peg while the gearbox is removed.
GEARBOX
CLUTCH
Never push the vehicle to try to start it;
- Fit the centring peg to locate the gearbox on the engine :
(impossible with an automatic gearbox).
(remove the converter retaining peg just before locating)
Lubrication
WARNING : With the safety programme selected, a snatching can be
The automatic gearbox is only lubricated when the engine is running
felt when changing from ‘‘P’’ ‘‘R’’ or ‘‘N’’ ‘‘R’’.
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XSARA RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Engines : NFZ - NFU - RFN
PROCEDURE BEFORE REPAIRS
AL 4 gearbox
Oil Quality
If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with
impurities : the oil is said to be "burnt".
DRIVESHAFTS
GEARBOX
This is characterised by a black colour and the presence of an unpleasant smell.
CLUTCH
ESSENTIAL : The gearbox must be replaced.
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RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA
Engines : NFZ - NFU - RFN
AL 4 gearbox only
PROCEDURE BEFORE REPAIRS
Oil level AL 4 (prior conditions).
- Vehicle in horizontal position.
- Check gearbox is not in back-up mode.
- Remove the oil filler plug (3).
- Add 0.5 litres extra oil into the gearbox.
- Foot on the brake, change through all the gears.
- Selection lever in position "P".
- Engine running, at idle.
- Oil temperature : 60°C (+8°C; -2°C), measured with the aid of a diagnostic tool.
DRIVESHAFTS
- Remove the oil level plug (3).
GEARBOX
CLUTCH
- Thread of oil then "drip-drip" : refit plug (3). Tighten 2.4 m.daN.
- "Drip-drip" or nothing : refit the plug (3).
- Stop the engine.
- Add 0.5 litres extra oil into the gearbox.
- Repeat the oil level procedure.
NOTE : The level is correct at the moment the thread of oil becomes drip-drip.
- Refit the oil filler plug (3). Tighten to 2.4 m.daN.
- Initialise the oil usage counter (open the diagnostic tool procedure).
B2CP31FD
241
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XSARA RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Engines : NFZ - NFU - RFN
PROCEDURE BEFORE REPAIRS (continued)
When the ECU detects an erroneous or absent valueon input or Reading the fault codes.
output :
Read the fault codes.
- It writes the fault in memory. - Absence of fault codes:
- For each associated context, it writes the context of the oldest fault - Carry out a measure of parameters.
in memory.
- It initiates a back-up mode strategy. Presence of anomalies:
DRIVESHAFTS
There are two types of back-up modes : - YES : Carry out the necessary repairs.
GEARBOX
- NO : Read the fault codes - engine ECU
CLUTCH
- The ECU makes replacement values available (relating to comfort, - Carry out a road test.
gear selection quality, loss of functions).
Following an initialisation of the ECU, for a certain period of time there
- Access to emergency programme (only 3rd gear and reverse are may be an inconsistent gear selection quality (while ECU parameters
available) are adapting to the gearbox).
To achieve a consistent standard, it will be necessary to carry out a
road test taking in frequent gear changes (auto-adaptive laws).
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RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA
Engines : NFZ - NFU - RFN
ECU : Downloading
Updating the gearbox ECU by downloading :
- Follow the procedure using the diagnostic tool.
The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
After the downloading operation, carry out the following:
A clearing of faults.
A pedal initialisation.
An initialisation of the auto-adaptives.
A recording of the value of the oil usage counter previously read.
DRIVESHAFTS
A road test.
GEARBOX
CLUTCH
ESSENTIAL : Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.
Updating the value of the oil usage counter.
Using PROXIA Using LEXIA or ELIT.
Access to reading and recording of the oil counter is via the menu : Access to reading and recording of the oil counter is via the menu :
"Configuration (integrated circuit button) / Oil counter ". "Oil counter ".
Adjustment of the oil counter value is done in incremental steps of 2750 units. Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
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XSARA RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Engines : NFZ - NFU - RFN
ECU : Downloading, Configuration, Initialisation (pedal) (continued)
Downloading. Pedal initialisation.
ECU downloading procedure : A pedal initialisation must be carried out in the following cases :
- Follow the diagnostic tooling procedure.
- Replacement of the automatic gearbox ECU.
A new ECU or downloaded update is always configured with the following
options : - Replacement of the automatic gearbox.
- SHIFT LOCK gear selection lever position.
- OBD outlet (emission standard L4). - Downloading of the ECU configuration.
DRIVESHAFTS
GEARBOX
CLUTCH
If the ECU is to be fitted to a vehicle without one or bothof these options: - Adjustment or replacement of the accelerator cable.
- Carry out a configuration which inhibits the diagnosis of the option(s)
concerned. - Replacement of the throttle potentiometer.
IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistentgear
selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes (auto-
adaptive laws).
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RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA
Engines : NFZ - NFU - RFN
SHIFT LOCK
- The shift lock is a system which locks the selection lever in the park position "P".
Unlocking the SHIFT LOCK (In normal operation)
- Switch on the ignition.
- Press and hold down the brake pedal.
- Using the selection lever, disengage from position P.
DRIVESHAFTS
NOTE : It is IMPERATIVE to disengage the gear selection lever from position "P" the minute
GEARBOX
CLUTCH
you start applying the brake pedal. Otherwise, release pressure on the brake pedal and then
try again.
Unlocking the SHIFT LOCK (In the event of a malfunction)
- Remove the cover (1).
- Unlock the shift lock (2) using a screwdriver.
- Using the selection lever, disengage from position "P".
B2CP268C B2CP269C
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XSARA 4 HP 14 AUTOMATIC GEARBOX
Engine : RFV
DRIVESHAFTS
GEARBOX
CLUTCH
Ref. Torque
X (mm) Y (mm) m.daN Tightening torques m.daN
letter
A 80 12 0.8
(1) Gearbox casing screw 1
B 80 10 0.6
C 75 12 0.8 (2) Oil dipstick tube nut 4.5
D 65 10 0.6 (3) Strainer cover
E 60 10 0.6 (4) Hydraulic valve block 0.8
Note : If replacing an automatic gearbox, it is ESSENTIAL also to replace the
heat exchanger, as well as the oil.
B2CP34RD B2CP34SC B2CP34TC
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4 HP 14 AUTOMATIC GEARBOX CONTROLS XSARA
Engine : RFV
Tightening torques m.daN.
(1) - Fixing to the body.
(2) - Gearbox bracket fixing.
(3) - Adjusting nuts.
DRIVESHAFTS
(4) - Gearbox selector fixing.
GEARBOX
CLUTCH
NOTE : Ball-joint lubrication
ESSO NORVA 275 (G9).
B2CP287D
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XSARA 4 HP 14 AUTOMATIC GEARBOX - CHECKS AND ADJUSTMENTS
Engine : RFV
Adjusting the gear selector
Tools
[1] Ball-joint extractor 9040-T.G2 Tool kit 9040-T
- Uncouple the ball-joint housing (1) from the selector lever using tool [1].
CAUTION : Do not twist the rod (2) of the selector cable when uncoupling.
- Gear lever in position N (Normal).
- Selector lever (5) in position N.
DRIVESHAFTS
- Loosen the nuts (3).
GEARBOX
CLUTCH
- Position the ball-joint housing (1) opposite the ball-joint (4).
- Fit the ball-joint housing (1) to the selector lever (5) ball-joint (4).
- Tighten the nut (3).
Check that :
- The gear selector works correctly in all the positions.
- The "starter" function only works in positions P and N.
B2CP010C B2CP27XC B2CP27YC
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4 HP 14 AUTOMATIC GEARBOX - CHECKS AND ADJUSTMENTS XSARA
Engine : RFV
Checks - Adjustments : Kick down cable
Preliminary conditions :
- Engine hot.
- Idling speed correct.
- Automatic cold start device out of action (according to equipment).
Accelerator cable adjustment :
- Remove the kick down cable (1) from the throttle quadrant.
- Pull out the sheath stop (2) and fit the spring clip (3) so as to obtain a small
DRIVESHAFTS
clearance.
GEARBOX
CLUTCH
- Press the accelerator pedal fully down.
- Ensure that the throttle is fully open.
Kick down cable adjustment:
- Pull the cable until the point of resistance.
(Start of kick down command A = 39 mm).
- The lug (4) must be positioned and crimped on the cable.
- Refit the kick down cable (1) on the throttle quadrant.
- Adjust the clearance (B) from 0.5 mm to 1 mm max. by tightening the nuts (5).
B2CP35GC B2CP35HC B2CP35JC B2CP35KC
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ALL TYPES DRIVESHAFTS - GEARBOXES
Tightening torques (m.daN) Gearbox oil seal mandrels
Driveshaft Driveshaft
Gearbox Engines Right Left Tool kit
bearing nut
CDZ-HDZ-HFX-KFX-KFW-NFZ NONE 24.5
MA/5
NFT-NFX-NFU-VJZ-VJY-VJX
MA/5 XSARA KFX
1.8 32
7114-T.W 7114-T.X 7116-T
BE4/5 NFZ - 6FZ - RFN - RHY
LFX - LFY - RFS - RFV
BE3/5 32.5
WJZ - DHY - RHY
DRIVESHAFTS
GEARBOX
4101-T.E1
CLUTCH
MB3 KFX 24.5 NONE 4601-T
+4601-T.E2
1 Seal extractor
RH / LH (-) 0338 C
AL 4 KFX - NFU - RFN 32.5 (-) 0338
(-) 0338 J1 (-) 0338 H1
+ (-) 0338 J2 +(-) 0338 H2
4 HP 14 RFV 32.5 9017-T.B 9017-T.C 9017-T
Tightening torque for wheel bolts : SAXO - XSARA = 8.5 m.daN
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AXLE GEOMETRY SAXO - All Types
Geometry of the axles at reference height.
Front height Rear height
H1 = R1 – L1 H2 = R2 + L2
H1 = Distance between the ground and H2 = Distance between the ground
the mounting face of the fixings. and the mounting face of the rear
R1 = Distance between the centre of crossmember.
the front wheel and the ground. R2 = Distance between the centre of
L1 = Distance between the centre of the the rear wheel and the ground.
front wheel and the mounting face of L2 = Distance between the centre of the
the fixings. rear wheel and the rear crossmember.
The values L1 and L2 are given in the table below.
C4CP0N2C Normal suspension Raised suspension C4CP0N3C
Front axle Rear axle Front axle Rear axle
Dimension L1 L2 L1 L2
Value (mm) 71 ± 10 mm 53 ± 6 mm 36 ± 10 mm 82 ± 6 mm
SUSPENSION
STEERING
Measure the dimension R1. Calculate the dimension H1 = R1 - L1.
AXLES
Measure the dimension R2. Calculate the dimension H2 = R2 + L2
Compress the suspension until the calculated values «H1» and «H2» are obtained.
NOTE : The difference in height between the two sides at the rear should be less than 7.5 mm.
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SAXO - All Types AXLE GEOMETRY
Geometry of the axles at reference height.
Front height Rear height
Reminder : Measuring the front height Reminder : Measuring the rear height
H1 = Distance between the ground and the mounting face of the fixings H2 = Distance between the ground and the rear crossmember
B3BP07UC B3BP07VD
The front heights H1 are measured between the ground and the mounting The rear heights H2 are measured between the ground and the mounting
face of the arm fixings (1) at the point «a». face of the rear crossmember (2) at «b» and «c».
SUSPENSION
STEERING
WARNING
AXLES
A < B = Positive figure: += TOE-IN
B3CP02UC A > B = Negative figure: –= TOE-OUT
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AXLE GEOMETRY SAXO - All Types
Geometry of the axles at reference height.
Normal suspension Raised suspension
Front Rear Front Rear
TU9M TU1M+ (**) TU9M TU1M+ (**)
Engines TU1M+ TU3JP – TU5JP All types TU1M+ TU3JP – TU5JP All types
(*) TU5J4 – TUD5 (*) TU5J4 – TUD5
Steering Manual Manual Assisted Manual Manual Assisted
Tracking 0° -0°10’ to 0°31’ -0°10’ to 0°31’ -0°16’ to -1°6’ -0°10’ to 0°31’ -0°10’ to 0°31’ -0°16’ to -1°6’
Toe-in mm -1 to -3 +1 to +3 +1.49 to +6.39 -1 to -3 +1 to +3 +1.49 to +6.39
Camber - 0°9’ ± 30’ - 0°40’ ± 30’ - 1°35 ’± 30’ - 0°9’ ± 30’ - 0°40’ ± 30’ - 1°35 ’± 30
Castor 2°13’± 30’ 3°14’± 30’ 2°13’± 30’3° 3°14’± 30’
King pin inclination 12°± 41’± 40’ 12°42’± 40’ 12°± 41’± 40’ 12°42’± 40’
(*) = Without assisted steering option and ABS. (**) = With assisted steering and ABS options.
SUSPENSION
STEERING
AXLES
WARNING : For the vehicle to be at reference height, compress the suspension until
the calculated values «H1» and «H2» are obtained.
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SAXO - All Types SPECIAL FEATURES : SUSPENSION - STEERING
EVOLUTIONS : Damper springs – Driveshafts – Wheel hubs.
Date of application : 01/1999 - RPO : 06/01/1999
Front suspension springs.
Vehicles concerned : Saxo all types.
Modification : 5 1/2 spirals instead of 6.
Driveshafts.
Vehicles concerned : Saxo all types, with or without ABS, except versions with 3 wheel bolts.
RH / LH transversal transmission.
- Tapered stem instead of cylindrical stem.
- Helicoidal instead of straight splines.
- Increased thread length.
Modification of the grease used.
Front wheel hubs.
- Helicoidal instead of straight splines.
Bearing assembly.
- Increased height of driveshaft nut.
- New bearing.
The driveshaft nut becomes common for wheels with both 3 and 4 bolts.
SUSPENSION
STEERING
Replacement parts.
AXLES
WARNING : These new components cannot be fitted on vehicles prior to RPO 8094 (06/01/1999).
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FRONT AXLE SAXO - All Types
Anti-roll bar Ø 18 and 22 mm Anti-roll bar Ø 19 and 21 mm (1) Suspension leg.
(3) Front anti-roll bar.
(9) Lower arm.
Tightening torques m.daN
(2) Anti-roll bar bearing fixing on the bodyshell 5.5 ± 0.2
(4) Anti-roll bar bearing fixing on the lower arm 2.2 ± 0.2
(5) Suspension leg upper fixing 2.1 ± 0.2
(6) Lower ball-joint fixing screw 3.8 ± 0.4
(7) Anti-roll bar link rod fixing 7 ± 0.6
(8) Suspension arm rear fixing nut 4.2 ± 0.4
(9) Suspension arm front fixing 8.5 ± 0.8
B3CP02SD
Suspension – Front anti-roll bar
TU9M (2) TU9M (2) TU9M TU5JP TU1M+ (3) Raised suspension LPG
TU1M+ (1) TU3JP (3) France
TU1M+ (2) TU1M+ Export Cylindrical Ring-shaped
TU3JP TUD5 TU5JP(3) - TU5J4 Administration
SUSPENSION
STEERING
Ø Anti-roll bar None 21 19 18 22 21 19 21 19
AXLES
(1) =With airbag. (2) = Without option. (3) = VTS level.
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SAXO - All Types REAR AXLE
(1) Rear axle.
(2) Damper.
(5) Rear suspension arm.
(7) Rear brake drum.
(9) Torsion bar.
The Anti-roll bar is located inside the tube of the rear axle.
Tightening torques m.daN.
(3) Damper upper fixing screw 10 ± 1
(4) Damper lower fixing screw 10 ± 1
(6) Stub nut 20 ± 1
(8) Rear axle fixing bolt 8.7 ± 1
SUSPENSION
STEERING
AXLES
B3DP02ND
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REAR AXLE - SUSPENSION SAXO - All Types
Torsion bar
TU9M (1)-TUD5 (1)
TU9M - TU1M+ - TU3JP TU1M+ LPG
TU1M+ (1) (2) – TU3JP (2)
TU5JP – TUD5 TUD5 (3)
TU5J4
Torsion bar Ø (mm) 19 17.9 18.3
Colour reference LH : 2 rings Black White Green
Torsion bar RH : 1 ring
(1) = Entreprise. (2) = VTS trim level (3) = With raised suspension
Anti-roll bar
TU9M (1) Raised suspension
TU1M+ (3)
TU1M+(2)
TU3JP (3)
TU9M - TU1M+ TU3JP TU1M+ LPG
TU5JP (3) France Export
TU5JP
TU5J4
TUD5
Anti-roll bar Ø
None 18 22 15 18 15
SUSPENSION
(mm)
STEERING
AXLES
(1) =With airbag. (2) = With airbag or assisted steering or ABS. (3) = VTS trim level.
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SAXO - All Types STEERING SPECIFICATIONS
Manual steering
Tyres 155/70 R13 165/70 R13 165/65 R14 NOTE : The steering assembly is secured to the bulkhead..
Pinion (no. of teeth) 6
Length of the steering track rods
Rack (no. of teeth) 28 (Between the centre lines of the ball-joints).
Rack travel 80 72 Pre-adjustment = 520 mm.
Stop (colour) Black White
Power-assisted steering
Tyres 165/70 R13 165/70 R14 185/55 R14
Pinion (no. of teeth) 7
Rack (no. of teeth) 28
Rack travel 68
Stop (colour)
SUSPENSION
STEERING
AXLES
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MANUAL STEERING SAXO - All Types
Tightening torques (m.daN)
1 - Airbag 7 - Pivot ball-joint nut 3.5
2 - Airbag fixing to steering wheel 0.8 8 - Lock nut M14 4.5
3 - Steering wheel fixing 3 8 - Lock nut M16 5
SUSPENSION
STEERING
4 - Steering column fixing 2.3 9 - Track rod articulation 2.1
AXLES
5 - Steering cardan joint fixing 2.3 10 - Splined coupling fixing to steering rack 2.4
B3EP02UD
6 - Fixing to bulkhead 2.2
B3EP09SC B3EP09TD
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SAXO - All Types POWER-ASSISTED STEERING
Tightening torques (m.daN)
1 - Airbag 8 - Track rod lock nut M16 5
2 - Airbag fixing to steering wheel 0.8 9 - Track rod articulation 2.1
3 - Steering wheel fixing 3 10 - Splined coupling fixing to steering rack 2.4
4 - Steering column fixing 2.3 11 - Steering ram to splined coupling 8
5 - Steering cardan joint fixing 2.3 12 - Steering ram to casing 8
SUSPENSION
STEERING
6 - Fixing to bulkhead 2.2 13 - Nut fixing the pinion to the bearing 1.5
AXLES
7 - Pivot ball-joint nut 3.5 14 - Valve/casing fixing 0.7
8 - Track rod lock nut M14 4.5
B3EP02TD B3EP02WD
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POWER STEERING (continued) SAXO - All Types
Power steering system
WARNING : Saxo all types except diesel without aircon
1 -
Power steering
2 -
Oil dispensing valve
3 -
Power-assisted steering ram
4 -
Low pressure pipe
5 -
High pressure pipe
6 -
Upper reservoir
7 -
Power steering electro-pump unit and built-in
lower reservoir
8 - Flexible mounting
9 - Electro-pump unit bracket
Tightening torques (m.daN)
Pump support fixing 2
Pump fixing to support 2
High pressure pump
Electro-pump connection 2
Power steering valve connection 2.5
SUSPENSION
STEERING
Low pressure pump
AXLES
Electro-pump connection 2.5
NOTE : Fluid type TOTAL Fluide ATX capacity : 0.950 L. Power steering valve connection 2.5
B3EP09UD
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SAXO - All Types POWER STEERING (continued)
POWER STEERING SYSTEM
WARNING : Saxo diesel with aircon
Description.
NOTE : The power steering system on vehicles without aircon is supplied
by a mechanical pump driven by the accessories drive belt.
(6) Power steering mechanism.
(7) Upper reservoir.
(8) Lower reservoir.
(9) Radiator.
(10) Power steering pump.
(11) The grooves on the connector (6) indicate that the pump (5) is
constant flow.
Max. pressure : 80 Bars.
Pulley diameter : 112 mm.
Fluid quality : TOTAL Fluide ATX
Capacity : 1.55 litres.
SUSPENSION
STEERING
AXLES
B3EP12XD
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AXLE GEOMETRY XSARA - All Types
Front and rear measuring points
XSARA # 09/2000 XSARA 09/2000 #
Front height Rear height Front height Rear height
B3CP046D
H1 = Dimension between the centre of the front suspension arm mounting and the ground.
H2 = Dimension between the contact face of the rear mounting and the ground.
R1 = Front wheel radius under load.
R2 = Rear wheel radius under load.
L1 = Distance between the centre of the wheel and the centre of the front suspension arm mounting.
SUSPENSION
STEERING
L2 = Distance between the centre of the wheel and the contact face of the rear mounting on the bodyshell.
AXLES
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XSARA - All Types AXLE GEOMETRY
Reference heights
Tools [1] Gauge for measuring the radius of wheels with 4 bolts : 8006-T
Setting the reference height.
Front Rear
Measure the dimension «R1». Measure the dimension «R2».
Calculate the dim. H1 = R1 - L1. Calculate the dim. H2 = R2 + L2.
Compress the suspension until the values (H1) and (H2) are obtained.
B3CP04AD NOTE : The difference in height between the two sides should be less than 10 mm.
XSARA # 09/2000
Front axle Rear axle
Height H1 =R1 – L1 H2 = R2 + L2
All types H1 = R1 – 85.5 mm H2 = R2 + 83 mm
XSARA 09/2000 #
Front axle Rear axle
SUSPENSION
STEERING
2.0i 16V All Types All Types 2.0i 16V Saloons All Types All Types
AXLES
Engines (except 2.0i 16V and CRD) Estates
(RFS) (except 2.0i 16V and CRD) CRD (RFS) CRD
Reference heights 115.5 90.5 75.5 73 83 88 103
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AXLE GEOMETRY XSARA - All Types
Values of the front and rear suspensions, at reference height
ESSENTIAL : When checking the suspensions, the vehicle should be at reference height.
Tools used :
Compress the suspension, to obtain the values at reference height.
[1] Set of two suspension compressors : 9511-T.A
[2] Set of four straps : 9511-T.B
[3] Set of four shackles : 9511T.C
SUSPENSION
STEERING
WARNING
AXLES
A < B = Positive figure: += TOE-IN
B3CP04LC A > B = Negative figure: –= TOE-OUT
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XSARA - All Types AXLE GEOMETRY
Values of the front and rear suspensions, at reference height
XSARA # 09/2000
Front axle
Adjustable Steering All Types Rear axle
mm - 1.5 ± 1 Adjustable
Tracking YES (Toe-out)
0° - 0°15' ±10' mm 4.5 ± 1 mm
Tracking (Toe-in)
Castor 1° 30 ± 40’ 0° NO 0°45' ± 10'
King pin inclination NO 10° 50’ ± 1° Camber - 1° 20' ± 40’
Camber 0° ± 1°
XSARA 07/1999 # 09/2000
Front axle
Adjustable Steering All Types Rear axle
mm - 1.5 ± 1 Adjustable
Tracking YES (Toe-out)
0° - 0°15’ ± 10’ mm 4.5 ± 1 mm
Tracking (Toe-in)
SUSPENSION
Castor 3° ± 40’ (*) 0° NO 0°45' ± 10'
STEERING
AXLES
Camber - 1° 20' ± 40’
King pin inclination NO 10° 50’ ± 1°
Camber 0° ± 1° (*) = Estates, LPG, DRC (difficult road conditions) Castor remains at 1°30’ ± 40’
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AXLE GEOMETRY XSARA
Values of the front and rear suspensions, at reference height
XSARA 09/2000 #
Front axle
Adjustable All types (except 2.0i 16V) 2.0i 16V All Types CRD
mm - 1.5 ± 1
Tracking YES
0° - 0°15' ±10'
Castor 3° ± 40’
King pin inclination NO 10° 40’ ± 1° 11° ± 1° 10° 40’ ± 1°
Camber 0° ± 1°
Rear axle
All types
Adjustable 2.0i 16V Estates All Types CRD
(except 2.0i 16V)
mm 4.6 ± 1 5.2 ± 1 4.4 ± 1 3.5 ± 1
SUSPENSION
STEERING
Tracking
NO 0° 41’ ± 10’ 0° 47’ ± 10’ 0° 40’ ± 10’ 0° 32’ ± 10’
AXLES
0°
Camber - 1° 30’ ± 1°
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XSARA - All Types AXLE GEOMETRY
a = Angle which defines the tracking between the front and rear axles.
Its value must not exceed 12'
SUSPENSION
STEERING
AXLES
B3CP04UC
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FRONT AXLE XSARA - All Types
Tightening torques (m.daN).
(1) Damper nut 4.5 ± 0.4
(2) Cup screw 2.5 ± 0.3
(3) Suspension leg
(4) Anti-roll bar link rod upper ball-joint 3.7 ± 0.3
(5) Suspension leg pivot (hollow pivot) 4.5 ± 0.5
(5) Suspension leg pivot (pivot «H») 5.5 ± 0.5
(6) Anti-roll bars
(7) Anti-roll bar link rod lower ball-joint 3.7 ± 0.3
(8) Pivot lower ball-joint 4 ± 0.4
(9) Driveshaft nut 32.5 ±2.5
(10) Wheel bolt 9±1
(11) Lower arm front mounting 7.6 ± 0.7
(12) Lower arm rear mounting and anti-roll bar bearing 6.8 ± 0.6
(13) Screw under rear mounting
(14) Ball-joint fixing on lower arm 3.1 ± 0.3
SUSPENSION
Subframe to bodyshell fixing screw 5± 0.5
STEERING
AXLES
Vehicles 09/2000 # are all equipped 8.5 ± 0.8
as standard with ventilated discs.
B3CP040P B3CP041D
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XSARA - All Types FRONT AXLE
XSARA # 09/2000
Anti-roll bars
Engines Diameter Colour reference
1.4i - 1.5 D - 1.9 TD 18 Violet
1.6i - 1.8i - 1.8i 16V - 1.9 TE 19 Blue
XSARA 09/2000 #
Anti-roll bars
Engines Diameter Colour reference
1.4i et 1.9D Saloons All Types 19 Blue
1.6i-2.0i 16V (RFV) - 2.0 HDi All Types
20 Yellow
except Saloons 1.4i et 1.9 D
SUSPENSION
STEERING
2.0i 16V (RFS) 21 White
AXLES
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FRONT AXLE XSARA - All Types
Evolution : Suspension arm ball-joint
09/98 # Evolution :
Application from RPO : 7968.
New components :
- Suspension arm ball-joint.
- Pivot.
Old fitting ØA = 16 mm.
New fitting ØA = 18 mm.
Repair requirements.
ESSENTIAL : Swapping of old and new components is forbidden.
It is permitted to fit a new pivot/ball-joint assembly on one side of an old
vehicle.
SUSPENSION
Replacement Parts.
STEERING
AXLES
The old components are still available from Replacement Parts.
B3CP054D
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XSARA - All Types FRONT AXLE
XSARA # 07/1999 XSARA 07/1999 # 09/2000 XSARA 07/1999 # 09/2000
The angle of castor changes to 3° except for
LPG vehicles, DRC vehicles, and Estates All
Types.
DRC = Difficult Road Conditions : this type of
vehicle has axles and suspensions designed for
driving on rough road surfaces.
Lug "a" to the rear.
Lug "a" to the front.
Pivot ball joint
Manual steering, groove at "b".
Power-assisted steering, groove at "b".
SUSPENSION
STEERING
NOTE : Vehicles after 09/2000 # are all equipped as standard with ball-joints without the groove at «b».
AXLES
B3CP042D B3CP049C B3CP043D
272
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REAR AXLE XSARA - All Types
Tightening torques (m.daN)*
(1) Anti-roll bar lever 3.2 ± 0.3
(2) Anti-roll bar
(3) Transversal torsion bars
(4) Rear crossmember flanges 8.3 ± 0.8
(5) Front mountings 5.5 ± 0.5
(6) Rear mountings 4.5 ± 0.4
(7) Anti-vibration clamp.
(8) Damper pin 9.6 ± 0.9
(9) Stub axle nuts (lubricated) 18.5 ± 1
NOTE
- The RH torsion bar can be identified by 1 paint line.
SUSPENSION
STEERING
AXLES
- The LH torsion bar can be identified by 2 paint lines.
B3DP04SP
273
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XSARA - All Types REAR AXLE
XSARA # 09/2000
Torsion bars (mm) Torsion bars (mm) Torsion bars (mm)
Vehicles Diameter Colour reference Diameter Colour reference
All Types except VTS 18.7 Yellow
20
VTS 19.3 Violet
XSARA 09/2000 #
Vehicles Torsion bars (mm) Anti-roll bars (mm)
Engines Diameter Colour reference Diameter Colour reference
3-door Entreprise 19.3 Violet 19 Orange
1.4i - 19.D 3- and 5-door TT 18.7 Yellow 18 Blue
exc. Entreprise
Estates All types 20 Grey 20 Green
1.6i 16V-2.i 16V 3- and 5-door TT 19.3 Violet 19 Orange
2.0 HDi Estates All types 20 Grey 20 Green
SUSPENSION
2.0i 16V 3-door VTS 21 Green clair 23 Without colour,
STEERING
or white sticker
AXLES
3- and 5-door TT 19.3 Violet 19 Orange
Grand Export «DRC»
Estates All types 20 Grey 20 Green
274
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REAR AXLE XSARA - All Types
Evolution : Rear hub nut
Old # 15/12/1999. New 15/12/1999 #
Evolution :
- New rear hub nut (3).
- Washer discontinued (2).
Old fitting (A)
(1) Rear hub nut.
(2) Thrust washer.
ESSENTIAL : Tighten to : 27.5 ± 2.7 m.daN
New fitting (B)
(3) Rear hub nut.
ESSENTIAL : Tighten to : 25 ± 2.5 m.daN.
NOTE : It is possible to have both types of fitting on the same axle.
The old nut (1) requires the fitting of the thrust washer (2).
WARNING : do not fit a thrust washer (2) with a new nut (3).
ESSENTIAL: Respect the tightening torque to be applied when fitting.
SUSPENSION
STEERING
WARNING: Identify the type of fitting, before starting a repair.
AXLES
B3DP08AD
275
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XSARA - All Types REAR AXLE
Operating clearance - X = 1 to 1.4 mm. - The front mountings are aligned at an angle of 45° in relation to the vehicle’s axis.
- The rear mountings are in parallel with the vehicle’s axis.
NOTE : The RH torsion bar can be identified by NOTE : There are two suppliers for the mountings:
1 paint line. - RBT, identified by a Green or Yellow painted dot on the side of the mounting.
SUSPENSION
The LH torsion bar can be identified by 2 paint
STEERING
- PAULSTRA, identified by a Black painted dot on the side of the mounting.
AXLES
lines. It is ABSOLUTELY FORBIDDEN to swap components of different suppliers.
B3DP04TC B3DP04UD
276
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REAR DAMPER XSARA - All Types
XSARA # 09/2000
Adjusting the rear dummy damper
All types Adjustment of X = 288 mm.
XSARA 09/2000 #
Adjusting the rear dummy damper
Lengths of the rear dummy damper (mm)
Engines
Normal driving Grand export
1.4i Saloons All Types 346
346
1.9 D
1.6i 16V 3-door 339
339
1.6i 16 V 5-door
346
2.0i 16V (RFN)-2.0 HDi
2.0i 16V (RFS) 318
Estates and
SUSPENSION
336 342
STEERING
Entreprise all types
AXLES
E5AP14WC
277
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XSARA - All Types MANUAL STEERING SPECIFICATIONS
Steering wheel - Manual steering
- (a) : L.H.D./R.H.D = White.
- (L) : Shaft length = 311 ± 1.5 mm.
- (1) Steering wheel fitted with AIRBAG.
(according to equipment).
- (4) Steering column adjustment lever.
Tightening torques (m.daN).
- (2) AIRBAG to steering wheel fixing : 0.8
- (3) Steering wheel fixing : 3.3
- (5) Steering column to support fixing : 2.3
- (6) Steering cardan joint fixing : 2.3
- (b) = Locating bush.
SUSPENSION
The locating bush must be centred in the reference window
STEERING
before tightening the cardan bolts (6).
AXLES
B3EP08PD
278
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MANUAL STEERING SPECIFICATIONS XSARA - All Types
Manual steering
Tightening torques (m.daN)
(7) Pivot ball-joint nut :4
(8) Link rod lock nut : 4.5
(9) Ball-joint on steering rack :6
(10) Fixing on cradle :5
(11) Plunger flange screw : 1.2
SUSPENSION
STEERING
AXLES
B3EP042D
279
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XSARA - All Types MANUAL STEERING SPECIFICATIONS
Manual steering (continued)
Number of teeth
Steering rack Number of
Steering stop steering wheel Steering ratio
travel
colour code turns
(mm) Pinion Steering rack
6 teeth (13)
L.H.D. 73.5 29 4.3 22/1
(RH helix) Yellow thickness 14 mm
- Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm
(Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).
SUSPENSION
STEERING
AXLES
280
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POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types
Steering wheel - Power-assisted steering
- (a) : L.H.D. = Blue.
: R.H.D. = White.
- (L) : Shaft length = 311 ± 1.5 mm.
- (1) Steering wheel fitted with AIRBAG.
(according to equipment).
- (4) Steering column adjustment lever.
Tightening torques (m.daN).
- (2) AIRBAG to steering wheel fixing : 0.8
- (3) Steering wheel fixing : 3.3
- (5) Steering column to support fixing : 2.3
- (6) Steering cardan joint fixing : 2.3
- (b) = Locating bush.
The locating bush must be centred in the reference
window before tightening the cardan bolts (6).
SUSPENSION
STEERING
AXLES
B3EP08QD
281
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XSARA - All Types POWER-ASSISTED STEERING SPECIFICATIONS
Power-assisted steering
Tightening torques (m.daN)
(7) Pivot ball-joint nut :4
(8) Link rod lock nut : 4.5
(9) Ball-joint on steering rack :6
(10) Fixing on subframe :5
(11) Hydraulic pipe connection : 2.5
(12) Valve to housing fixing : 1.2
(13) Plunger flange screw : 1.2
(14) Screw fixing the steering ram to the housing : 5.5
(15) Nut fixing the steering ram to the yoke : 5.5
SUSPENSION
STEERING
AXLES
B3EP08RD
282
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POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types
Power-assisted steering (continued)
Steering rack Number of teeth Number of
travel steering wheel Steering ratio
(mm) turns
Pinion Steering rack
(*)
L.H.D. 71.7 28 3.3 18.8/1
(RH helix)
Steering valve
Vehicles Protector colour Number of teeth (*)
All types (except 1.8i 16V - 1.9TD) BLACK 7
1.8 i 16V - 1.9 TD ORANGE 8
SUSPENSION
STEERING
AXLES
- Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm
Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).
283
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XSARA - All Types POWER-ASSISTED STEERING SPECIFICATIONS
Power-assisted steering assembly
Tightening torques (m.daN)
High pressure tube (Rubber seal pump side)
- Power-assisted valve and pump union : 2.5
Return pipe.
- Power-assisted valve union : 2.5
(16) - Upper front fixing (E3) : 2.5
(17) - Upper rear fixing (E3) : 2.2
(18) - Fixing (E3) : 2.2
Tightening sequence.
- Tighten screws (16) and (18)
- Lightly tighten screw (17), then fully tighten.
Power-assisted steering system capacity = 1 litre.
Oil type: TOTAL FLUIDE ATX. Pressure switch on the pressure circuit.
SUSPENSION
- Switch opens 30 to 35 Bars.
STEERING
SAGINAW Pump adjustment = 100 Bars ± 5.
AXLES
Pump shaft threading 3/8 - 16 threads per inch. - Switch closes 25 bars.
- Tighten to : 2 m.daN.
B3EP045D
284
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AXLE GEOMETRY XSARA PICASSO - All Types
Measurements at reference height.
Front height Rear height
H1 = R1 - L1 H2 = R2 - L2
H1 = From the front suspension arm linkage bolt axis to the ground. H2 = From the rear axle flexible mounting face to the ground.
R1 = Radius of the front wheel when laden. R2 = Radius of the rear wheel when laden..
L1 = From the centre of the wheel to the front suspension arm linkage L2 = From the centre of the wheel to the rear axle flexible mounting
SUSPENSION
STEERING
bolt axis face
AXLES
B3CP05BC B3CP058D B3DP079C
285
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XSARA PICASSO - All Types AXLE GEOMETRY
Measurements at reference height (continued).
(The ref. height of the vehicle is set as per the table below
Front axle Rear axle
Front axle Rear axle
H1 = R1 – 90.5 mm H2 = R2 + 7 mm
Measure the radius of the front wheel : R1. Measure the radius of the rear wheel: R2.
Calculate dimension H1. Calculate dimension H2.
SUSPENSION
STEERING
AXLES
Compress the suspension to obtain the calculated values.
The difference in height between the two sides should be less than 10 mm.
B3CP05BC B3CP05AC B3DP079C
286
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AXLE GEOMETRY XSARA PICASSO - All Types
Measurements at reference height (continued)
NOTE : To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point.
WARNING : The values shown should only be used as guides. In case of doubt, check the settings at reference height (See page 286)
Front height Rear height
B3CP05BC B3CP058D H1’ = Measurement from the jacking point. B3DP079C
L1’ = R1 – H1’
L2 = R2 – H2
Compress the suspension to obtain the calculated values.
SUSPENSION
STEERING
Engines 1.6i – 1.8i 16 V – 2.0 HDi
AXLES
L1 90.5 mm
L1’ 124 mm
287
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XSARA PICASSO - All Types AXLE GEOMETRY
Measurements at reference height (continued).
Compress the suspension to obtain the calculated values (see page : 287)
Front axle Rear axle
King pin Camber Tracking Camber
Vehicles Tracking Castor inclination
Adjustable ( Non-adjustable ) Adjustable
0 mm ± 1mm 4.8 mm ± 1mm
All types 3° ± 20’ 10° 45’ ± 30’ 0° ± 30’ 1°20’ ± 20’
- 0°09’à + 0°09’ 0° 43’ ± 0° 09’
NOTE : When checking axles, the vehicle should be at reference height.
WARNING
A < B = Positive figure: += TOE-IN
A > B = Negative figure: –= TOE-OUT
SUSPENSION
STEERING
AXLES
All types Ground clearance
(*) = Fuel tank full.
B3CP02UC No load 150 mm (Minimum value)
288
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FRONT AXLE XSARA PICASSO - All Types
Tightening torques m.daN.
(1) Damper nut : 4.5 ± 0.4.
(2) Cup screw : 2.5 ± 0.3.
(3) Suspension arm.
(4) Anti-roll bar link rod ball-joint : 3.7 ± 0.3.
(5) Suspension arm swivel : 4.5 ± 0.4.
(6) Anti-roll bar
(7) Anti-roll bar link rod ball-joint : 3.7 ± 0.3.
(8) Lower swivel ball-joint : 4 ± 0.4.
(9) Hub nut : 32.5 ± 2.
(10) Wheel bolt : 9 ± 1.
(Face and threads not lubricated).
(11) Lower arm front pivot : 7.6 ± 0.7.
(12) Lower arm rear pivot and
anti-roll bar bearing : 6.8 ± 0.6.
(13) Screw under rear pivot : 3.7 ± 0.3.
Fixing bolt : subframe on bodyshell : 8.5 ± 0.8.
Anti-roll bar
SUSPENSION
STEERING
AXLES
Engines Diameter Colour mark
Damper upper bracket : NFZ-6FZ
Lug «a» to the front. 21 WHITE
B3CP056P B3CP057D B3CP043D RHY
289
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XSARA PICASSO - All Types REAR AXLE
Tightening torques m.daN.
(14) Front flexible mounting on subframe : 9.5 ± 0.9.
(15) Anti-roll bar bolt : 5.5 ± 0.5.
(16) Rear torsion bar
(17) Anti-roll bar
(18) Tubular axle
(19) Front flexible mounting on bodyshell : 4 ± 0.4.
(20) Rear upper arm.
(21) Wheel bolt : 9 ± 0.9.
(Face and threads not lubricated)
(22) Damper
(23) Rear flexible mounting on subframe : 5.5 ± 0.5.
(24) Damper pin nut : 11 ± 0.1.
(25) Stub axle nuts (lubricated) : 25 ± 0.2.
(26) Rear flexible mounting on bodyshell : 5.5 ± 0.5.
Torsion bar Anti-roll bar
Engine Ø (mm) Colour Ø (mm) Colour
mark mark
SUSPENSION
NFZ-6FZ-
STEERING
19.6 Pink 21 Orange
RHY
AXLES
NOTE : The RH torsion bar can be identified by 1 paint line.
B3DP078D - The LH torsion bar can be identified by 2 paint lines.
290
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REAR AXLE XSARA PICASSO - All Types
Evolution : Rear hub nut
Old # 15/12/1999. New 15/12/1999 #
Evolution :
- New rear hub nut (3).
- Washer discontinued (2).
Old fitting (A)
(1) Rear hub nut.
(2) Thrust washer.
ESSENTIAL : Tighten to : 27.5 ± 2.7 m.daN
New fitting (B)
(3) Rear hub nut.
ESSENTIAL : Tighten to : 25 ± 2.5 m.daN.
NOTE : It is possible to have both types of fitting on the same axle.
The old nut (1) requires the fitting of the thrust washer (2).
WARNING : do not fit a thrust washer (2) with a new nut (3).
ESSENTIAL: Respect the tightening torque to be applied when fitting.
SUSPENSION
WARNING : Identify the type of fitting, before starting a repair.
STEERING
AXLES
B3DP08AD
291
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XSARA PICASSO - All Types SUSPENSION
Height of the vehicle in running order
(The vehicle height, when in running order, is set according to the measurements shown in the table below).
The vehicle is said to be in running order when it is empty, with all
reservoirs full, including the fuel tank.
B3CP058D
Front Rear
H1 = R1 – L1 H2 = R2 – L2
SUSPENSION
STEERING
Engines 1.6i - 1.8 i 16 V 2.0 HDi Engine 1.6i - 1.8 i 16 V - 2.0 HDi
AXLES
L1 62.5 66.5 mm L2 51 mm
L1’ 96 100 mm
292
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SUSPENSION XSARA PICASSO - All Types
Checking the front and rear axles, vehicle in running order
Front axle Rear axle
1.6i - 1.8i 16 V
Adjustable 1.6i - 1.8i 16 V 2.0 HDi Adjustable 2.0 HDi
2 mm ± 1 mm 1.7 mm ± 1 mm Tracking YES 1.2 mm ± 1 mm
Tracking YES 0° 18’ ± 0° 09’ 0° 15’ ± 0° 09’ 0° 11’ ± 0° 09’
Castor 2° 54’ ± 20’ Camber NO 1° 15’ ± 20’
King pin
NO 10° 6’ ± 30’ 10° 12’ ± 30’
inclination
Camber 0° 20’ ± 30’ 0° 15’ ± 30’
WARNING
A < B = Positive figure: += TOE-IN
A > B = Negative figure: –= TOE-OUT
SUSPENSION
STEERING
AXLES
B3CP02UC
293
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XSARA PICASSO - All Types STEERING COLUMN SPECIFICATIONS
Left hand drive = Green marking.
Right hand drive = White marking.
(1) Steering wheel.
(4) Steering column adjustment.
Tightening torques m.daN.
(2) Airbag to steering wheel fixing 0.8 ± 0.1
(3) Steering wheel fixing 3.3 ± 0.6
(5) Steering column to support fixing 4±1
(6) Steering cardan joint fixing 2.3 ± 0.2
SUSPENSION
STEERING
AXLES
B3EP116D
294
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STEERING SPECIFICATIONS XSARA PICASSO - All Types
Tightening torques (m.daN)
(7) Pivot ball-joint nut 4 ± 0.4.
(8) Steering rod adjusting lock nut 4.5 ± 0.4.
(9) Ball-joint on steering rack 6 ± 0.6.
(10) Fixing steering on subframe 8 ± 0.8.
(11) Hydraulic pipe connection 2.4 ± 0.2
(12) Power steering valve 1.2 ± 0.2
(13) Plunger flange screws 1.2 ± 0.2.
(14) Steering ram screw on housing 9 ± 1.
(15) Steering ram screw on yoke 9 ± 1.
NOTE : When removing the steering, it is imperative to replace screws
(14) and (15) (New screws).
SUSPENSION
STEERING
AXLES
B3EP117D
295
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XSARA PICASSO - All Types STEERING SPECIFICATIONS
Steeringl Rack Number of teeth Number of Turning circle Turning circle
rack trave pinion in rack steering wheel turns between walls entre trottoirs
Left hand drive Hélice à gauche
71.7x2 28 Dents 3.22 12 m 11.48 m
Right hand drive Hélice à droite
Engines Steering valve
1.6i - 1.8i 16 V - 2.0 HDi No. of teeth : 7
Length of the steering link rods (pre-adjustment):
(Between ball-joint centres) = 392 mm
(Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint). = 412 mm.
SUSPENSION
STEERING
AXLES
296
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POWER-ASSISTED STEERING SPECIFICATIONS XSARA PICASSO - All Types
Tightening torques (m.daN)
Unions between pump unions and power steering valve 2 ± 0.3
(16) Fixing screw 2.2 ± 0.3
(17) Fixing screw 2.2 ± 0.3
(18) Fixing screw 2.2 ± 0.3
NOTE : Coat the threads with product ‘‘E3’’.
A pressure switch is implanted in the hydraulic piping between the high
pressure pump and the power steering valve.
- Opening pressure = 30 / 35 Bars.
- Closing pressure = 25 Bars minimum.
Tightening torque = 2 ± 0.2
Capacity of power steering circuit = 1 Litre.
Oil quality = TOTAL FLUIDE ATX.
Power steering pump : Supplier SAGINAW.
SUSPENSION
STEERING
Pump adjustment = 100 ± 5 Bars.
AXLES
B3EP118D
297
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BRAKES
SAXO - All types BRAKE SPECIFICATIONS
(1) Compensator integral with the wheel cylinder. 1.1 i - 1.4 i 1.6 i
1.0 i 1.6 i
1.5 D 1.6 i 16V
(2) Load sensitive compensator.
Manual steering Power-assisted steering without ABS
Master cylinder 20.6 19 20.6 22.2
Master-vac 203.2 177.8 203.2 228.6
Ø Caliper/piston TEVES FR BENDIX Standard TEVES FN
makes 12/45 4/48 48/48
mm
Ft Non-ventilated 238 247
Disc
Ventilated 247
Disc thickness/min. thickness 8/6 10/8 20.4/18.4
VALEO F 714 GALFER 3726
Brake pad grade TEXTART 4900 AS - FM 380
ABEX 966 TEXTART 4009
Cylinder or caliper 19 30
Ø
Drum / Ø max. 165/167 180/182
mm
Disc Non-ventilated 247
Rr Disc thickness/min. thickness 8/6
Make BENDIX RAD BENDIX S4
Brake lining grade DON 8259 AS FM 380
Compensator (1) 20 (2) 13
298
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BRAKES
BRAKE SPECIFICATIONS (continued) SAXO - All types
1.1 i - 1.4 i 1.6 i Entreprise
(1) Compensator integral with the wheel cylinder. 1.6 i
1.5 D 1.6 i 16V 1.0i-1.1i-1.5D
(2) Load sensitive compensator.
Power-assisted steering with ABS Manual steering
Master cylinder 20.6
Master-vac 203.2
Ø Caliper/piston BENDIX Standard TEVES FN BENDIX Standard
makes 4/48 48/48 4/48
mm
Ft Non-ventilated 247 247
Disc
Ventilated 247
Disc thickness/min. thickness 10/8 20.4/18.4 10/8
GALFER 3726
Brake pad grade JURID 519 AS FM 380
TEXTART 4009
Cylinder or caliper 20.6 30 19
Ø
Drum / Ø max. 203/205 180/182
mm
Disc Non-ventilated 247
Rr Disc thickness/min. thickness 8/6
Make LUCAS RAI BENDIX S4 BENDIX RAD
Brake lining grade JURID E 558 AS FM 380 DON 8259
Compensator (2) 13 (1) 20
299
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BRAKES
SAXO - All types BRAKES
B3FP06GC
Conditions
- Vehicle in running order - 5 litres of fuel.
- A driver (75 Kg).
Adjusting the brake limiter.
Adjusting the stop lamp switch. - Apply the brake pedal to close the limiter.
Clearance J = 2 to 3 mm. - Adjust using the screw (2) to obtain a clearance J of 0.5 to 2 mm.
After adjustment, tighten the lock nut (1) to 1 m.daN. NOTE : Do not touch (3) which has been adjusted at the factory.
B3FP06FC
300
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BRAKES
BRAKES (continued) SAXO - All types
ABS - 1.1 i - 1.4 i - 1.6 i Tightening torques (m.daN)
Removing the caliper
- 1.0 i and 1.1 i Manual steering
(except 1.0i Entreprise)
- Screw M8 3.2 ± 0.3
- Screw M12 12 ± 1.2
- 1.0i Enterprise - 1.1 i - 1.4 i
except 1.6 i)
- 2 Screw M12 12 ± 1.2
- 1.6 i
- 2 Screw M12 10.5 ± 1
B3FP10ND
301
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BRAKES
SAXO - All types HANDBRAKE (Adjustment)
Prior to adjustment.
- Release the handbrake.
- Drums rotating freely.
- No tight spot (If there is one, check if the primary or secondary cables are correctly routed).
- Check that all the parts slide and move correctly.
- Bleed the main circuit.
Adjustment.
- Set the brake to the 4th notch.
- Tighten the nut (3) until the rear brakes are applied.
- Check that:
- there is a total travel of between 4 and 7 notches.
- the two secondary cables (1) on the balance lever (2) move together.
- the wheels rotate freely when the brake is released.
- Check that the brake warning lamp comes on from the 4th notch.
NOTE : The handbrake operates on the rear wheels.
B3FP106JC
302
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BRAKES
PURGE DES BRAKES SAXO - All types
The brakes are bled :
- Using brake bleeding equipment, in which case the pressure of the equipment should be set to a maximum of 2 Bars.
IMPERATIVE order of bleeding
Wheel :
- Rear left.
- Front right.
- Rear right.
- Front left.
Top up to level using the brake fluid sold by the CITROEN Replacement Parts Division.
303
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BRAKES
XSARA # 09/2000 BRAKE SPECIFICATIONS
1.6 i
Without ABS 1.4 i 1.8 i 16 V 1.5 D 1.9 D 1.9 TD
1.8 i
Master cylinder 22.2 23.8 22.2
Master-vac 228.6
Ø BENDIX TEVES FN LUCAS TEVES FN
mm Caliper/piston makes
Série VZO 48 48 C542013 - 20 48
Ft Non-ventilated 247
Disc
Ventilated 247 266 247
Disc thickness/min. thickness 13/11 20.4/18.4 20/18 20.4/18.4
Brake pad grade ASFM 197 ASFM 380 ASFM 197
Cylinder or caliper 20.6 32 20.6
Ø
Drum / Ø max. 180/182 180/182 203/205
mm
Disc - ventilated 247
Rr Disc thickness/min. thickness 8/6
Make DON TEXTAR DON
Brake lining grade 8259 T 428 8259
Compensator cut-off in Bars 20 32 20 32
304
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BRAKES
BRAKE SPECIFICATIONS XSARA # 09/2000
1.6 i 1.8 D
With ABS 1.4 i 1.8 i 16 V 2.0 i 16 V 1.9 TD
1.8 i 1.9 D
Master cylinder 22.2 23.8 22.2
Master-vac 228.6
Ø
TEVES FN LUCAS LUCAS TEVES FN
Caliper/piston makes
mm 48 C542013 - 54 C572213N57 48
Ft Non-ventilated
Disc
Ventilated 247 266 283 247
Disc thickness/min. thickness 20.4/18.4 20/18 22/20 20.4/18.4
Brake pad grade ASFM 197 ASFM 380 ASFM 197
Cylinder or caliper 20.6 32 20.6
Ø
Drum / Ø max. 203/205 203/205
mm
Disc - ventilated 247
Rr Disc thickness/min. thickness 8/6
Make DON TEXTAR DON
Brake lining grade 8259 T 428 8259
Compensator cut-off in Bars 32 25 32
305
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BRAKES
XSARA # 09/2000 BRAKE SPECIFICATIONS
Without ABS With ABS
1.4i-1.9D 1.4i-1.6i 16V-1.9D
Saloon Estate 2.0 HDi 2.0i 16V
Master cylinder 23.8 23.8
Master-vac 228.6 228.6
Ø BOSCH ZOH 54/2 LUCAS
mm Caliper/piston makes
54 C57 22 13N/57
Ft Non-ventilated
Disc
Ventilated 266 283
Disc thickness/min. thickness 22/20 22/20
Brake pad grade FERF 769 ASFM 380
Cylinder or caliper 20.6 22 BENDIX Standard IV G - 32
Ø
Drum / Ø max. 203/205 228/230
mm
Disc - ventilated 247
Rr Disc thickness/min. thickness 8/6
Make JURID
Brake lining grade D 8259 E 558 JURID 519 T 428
Compensator cut-off in Bars 32
306
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BRAKES
BRAKE SPECIFICATIONS XSARA - All Types
- Tighten the nuts (1) to 2.3 m.daN.
- The clevis pin (2) is held in place by a plastic clip.
B3FP10YD
307
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BRAKES
XSARA - All Types BRAKE SPECIFICATIONS
Braking system specifications
1
- X braking circuit.
- Front : disc brakes, ventilated (according to model).
- Rear : drum brakes with automatic adjustment.
- Cable operated handbrake acting on the rear wheels.
(1) Hydraulic valve block «ABS Bosch 5.3».
2 (2) Load sensitive braking compensator (according to model).
B3FP09HC B3FP09JC
308
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BRAKES
BRAKE SPECIFICATIONS XSARA - All Types
Braking system without ABS (rear drum brakes) Braking system without ABS (rear disc brakes)
B3FP09ED B3FP09FD
309
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BRAKES
XSARA - All Types BRAKE SPECIFICATIONS
Braking system with ABS (rear drum brakes) Braking system with ABS (rear disc brakes)
B3FP09GD B3FP09KD
310
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BRAKES
REAR BRAKE SPECIFICATIONS XSARA - All Types
Evolution : Rear brake drum hub 01/1999 #
Old assembly New assembly
B3FP119D B3FP11AD
Evolutions.
New components : - Rear wheel stub. - Stop ring (ref. (4)). - Double shouldered washer (ref. (5))
NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at "a".
(1) Washer exterior diameter = 38 mm. Ref. "a": Figure from 1 to 6 cold-stamped.
(2) Stop ring (4) Stop ring.
(3) Circlip. (5) Double shouldered washer, exterior diameter = 48 mm.
NOTE : This assembly is equipped with either part (2) or part (3).
311
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BRAKES
XSARA - All Types REAR BRAKE SPECIFICATIONS
Evolution : Rear brake disc hub 01/99 #
Old assembly New assembly
B3FP11BD B3FP11CD
Evolutions
Fixing of the brake disc hub. Sealing of the brake disc hub.
New components: New components:
- Rear wheel stub. - Sealed bearing incorporated at "c" (ref. (6)).
- Double shouldered washer (ref. (7)). - Spacer without seal face (ref. (5)).
- Cap (ref. (8)).
NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at "c".
New assembly
Ref. "c". : Figure from 1 to 6 cold-stamped.
(5) Spacer without seal face. (7) Double shouldered washer, exterior diameter = 48 mm.)
(6) Sealed bearing incorporated at "b". (8) Cap.
312
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BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR XSARA - All Types
To perform any checks, it is necessary to calculate the weight on the rear axle in order to refer to the adjustment graphs.
Preliminary pre-check operations.
Calculate :
1) The rear weight of the vehicle (empty tank + 1 person) # Note the vehicle type Refer to table N° 1
2) The weight of fuel in the fuel tank # Note the fuel level Refer to table N° 2
3) The weight of options fitted to the vehicle # Note the vehicle options Refer to table N° 3
4) Add these three weights together to obtain the TOTAL REAR VEHICLE WEIGHT; remove all objects from the vehicle totalling more than
10 kg in weight.
5) Select the adjustment graph that corresponds to the vehicle model. (Refer to tableN° 4).
6) Check the brake pressure.
7) Adjust the load sensitive brake compensator if necessary.
Example
- The rear weight of the vehicle (empty tank + 1 person) = 412 kg
- The weight of fuel in the fuel tank (tank 1/2 full) = 18 kg
- The weight of options fitted to the vehicle (sun roof) = 8 kg
- Total rear vehicle weight = 438 kg
- Corresponding graph (Graph N° 1)
313
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BRAKES
XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)
(Weights in kg)
TABLE N° 1 (Rear weight of the vehicle (Empty tank + 1 person)). TABLE N° 2 (Weight of fuel in the fuel tank).
Trim level Type of fuel Petrol Diesel
X SX Exclusive VTS
Engine 5 litres 4 4
1.4 i 392 405 416 1/4 9 10
1.6 i 412 423 1/2 18 20
1.8 i 422 424 3/4 27 30
1.8 i 16 V 424 428 431 Non-ventilated 36 40
1.9 D 405 425 432
1.9 TD 436 449 447 450
(Weights in kg)
TABLE N° 3 (Weight of options fitted to the vehicle). TABLE N° 4 (Graph selection).
Option Vehicle Model Graph
Electric sun roof 8 1.4i - 1.6i - 1.8i - 1.8i (Automatic) - 1.9 D 1
Protective grille 5 1.8 i 16 V 2
Towing equipment (All models) 20 1.9 TD 3
314
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BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types
GRAPH N°1 GRAPH N°2
B3FP09XD B3FP09YD
315
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BRAKES
XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)
GRAPH N°3
B3FP09ZD
316
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BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types
TOOLS
- Braking pressure checking tool : 4140-T
CHECKING THE BRAKE PRESSURE
WARNING : Do not touch the plastic nut (1).
PRELIMINARY OPERATIONS
- Place the vehicle on a 4-column lift if possible.
- Fit tool 4140-T.
- Calculate the rear vehicle weight. (See pages : 313-314).
- Check that no hydraulic fluid is leaking and that the pipes are not being obstructed.
- Refer to the graph which corresponds to the vehicle type. ( See page: 315-316).
CHECKS
- Perform the checks between the wheels as follows : front left and rear right - front right and rear left.
- With the engine running, increase the pressure at the rear to obtain a front pressure of 60 bars.
ESSENTIAL : The checking pressure must be obtained by progressively increasing the pressure (never
reduce the pressure to adjust it).
- Check the increased measurement against the graph. (If the measurement is not within the limits, adjust the com-
pensator). (See page 318).
- To check that the compensator works correctly, increase the rear pressure to 100 bars. (If the measurement is not
within the limits, replace the compensator).
- Bleed the brake system and carry out a road test.
B3FP101C
317
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BRAKES
XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)
ADJUSTING THE COMPENSATOR
WARNING : Do not touch the plastic nut (1).
IMPORTANT : When loosening the nut (2), the spring (3) may suddenly force off the nut (2) and lock nut (4)
assembly. Calculate the spring length (3) before loosening the nut (2), and use a spanner to hold the lock-nut (4)
in place, thus restraining the spring.
- Loosen the nut (2) while ensuring the lock-nut (4) is held firmly in place.
- Adjust the length of the spring (3) :
- Reduce the spring length (3) to increase brake pressure.
- Increase the spring length (3) to reduce brake pressure.
- Tighten the nut (2) to 1.5 m.daN.
- Check the brake pressure.
B3FP101C B3FP102C
318
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BRAKES
HANDBRAKE XSARA - All Types
CHECKING AND ADJUSTING THE HANDBRAKE
- Remove the handbrake console.
- Jack up and chock the vehicle with the rear wheels hanging free.
- Check the correct routing of the brake cables under the vehicle.
- Apply and release the handbrake ten times.
- Set the handbrake to the 3rd notch.
- Tighten the nut (1) until the rear brakes are applied.
- Pull the handbrake lever vigorously 4 to 5 times.
- Set the handbrake to the 3rd notch.
- Check that the rear brakes are applied.
- Check that the wheels can be turned freely by hand with the
handbrake released.
- Lower the vehicle.
- Refit the handbrake console.
B3FP095D
319
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BRAKES
XSARA - All Types BLEEDING THE BRAKES
Bleeding :
The brakes can be bled either :
- using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars.
- or in the usual way.
IMPERATIVE order of bleeding
Wheels :
- Rear Right.
- Rear Left.
- Front Right.
- Front Left
Top up using brake fluid supplied by CITROEN Replacement Parts
320
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BRAKES
BRAKE SPECIFICATIONS XSARA PICASSO - All Types
NOTE : On models equipped with ABS, there is
no load-sensitive braking compensator. 1.6 i 1.8 i 16 V 2.0 HDi
Master cylinder 23.8
Master-vac 254
Ø Caliper/piston
LUCAS C 54
makes
mm
Fr Non-ventilated
Brake disc
Ventilated 266
Disc thickness/min. thickness 20.4 / 18.4
Brake pad grade AS-FM 380
Cylinder or caliper 22.2
Ø
Drum / Ø max. 228/230
mm
Non-ventilated disc
Rr Disc thickness/min. thickness
Make LUCAS
Brake lining grade ABEX 4930/2
Compensator 35/75
321
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BRAKES
XSARA PICASSO - All Types BRAKE SPECIFICATIONS
Braking system specifications
- ‘‘X’’ braking circuit.
- Front : disc brakes, ventilated
- Rear : drum brakes with automatic wear adjustment.
- Cable operated handbrake acting on the rear wheels.
- Rear: load-sensitive braking compensator (non-ABS models)
- (1) Hydraulic valve block ‘‘ABS Bosch 5.3’’.
- (2) Load sensitive rear braking compensator.
B3FP11VD B3FP08ND
322
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BRAKES
BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO - All Types
Without ABS With ABS
B3FP11WD B3FP11UD
323
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BRAKES
XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
Tools [1] Brake pressure checking tool : 4140-T
Checking procedure Determining the rear weight of the vehicle
Determine the weight on the rear axle and then refer to the adjustment Refer to the tables of different weights.
graphs. To obtain the rear weight of the vehicle, add the following weights :
The allocation table enables you to choose which graph to use for each - Rear weight of the vehicle (tank empty + 1 person).
type of vehicle. - Weight of fuel in the fuel tank.
Connect the tool [1] in order to check the rear pressure values relative to - Weight of the options on the vehicle.
the front pressures (60 and 100 bars). Remove from the vehicle any object that could weigh more than 1 Kg.
Rear weight of the vehicle (tank empty + 1 person) Masse carburant dans le réservoir.
Note the vehicle type. Relever le niveau du carburant du véhicule et en déduire la masse
Consult the correspondence table. d’après le tableau.
Level of fuel Weight of fuel in the fuel tank (Kg)
Engine type Rear weight (tank empty + 1 person)
(Litres) Petrol Diesel
NFZ 542 5 4 4
6FZ 531 1/4 11 12
RFN 532 1/2 22 24
RHY 540 3/4 33 36
Full 44 48
324
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BRAKES
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types
Tools [1] Brake pressure checking tool : 4140-T
Example.
Type of vehicle = TU5JP+
Rear weight (tank empty + 1 person). = 542 Kg.
Fuel tank half full = 22 Kg
Sun roof = 10 Kg
Rear weight of the vehicle = 542 + 22 + 10 = 574 Kg.
Weight of the options on the vehicle
Note the options on the vehicle and deduce the weight according to
this table
Options Weight (Kg) Table of allocation of graphs
Electric sun roof 10 Vehicle engine version Graph N°
Bicycle carrier 5
NFZ – RHY 1
Roof bars 4
6FZ 2
Refrigeration/heating module 10
Under-engine shield 9 NFZ – RHY (CRD) 3
Towbar all versions 19 6FZ – RFN (CRD) 4
325
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BRAKES
XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
GRAPH N°1 GRAPH N°2
B3FP09XD B3FP09YD
Key :
P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.
M = Weight (in Kg). b = Front pressure 100 ± 3 Bars.
326
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BRAKES
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types
GRAPH N°3 GRAPH N°4
B3FP09ZD B3FP100D
Key :
P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.
M = Weight (in Kg) b = Front pressure 100 ± 3 Bars.
327
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BRAKES
XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
CHECKING THE BRAKING PRESSURE
Preliminary operations :
- The vehicle should be placed on all 4 wheels, prefera-
bly on a lift. - Compare the value noted with the graph.
- The tool [1] (in good working order) in place. - If the value is outside the tolerance, adjust the
- Rear weight of the vehicle determined. compensator.
- Check there are no hydraulic leaks. - In order to check that the compensator is working
- Check the absence of pinching on the pipes. properly, note the rear pressure when the front
- Refer to the graph corresponding to the vehicle engine pressure is 100 ± 3 Bars.
version. - If the value is outside the tolerance, replace the
- Checks are done between the following components : compensator.
Front LH wheel and rear RH wheel. - Any large discrepancy between the two circuits
Front RH wheel and rear LH wheel.. will mean that the braking compensator should be
replaced.
- On the vehicle, engine running, note the rear pressure
- After completing these operations, bleed the bra-
when the front pressure is 60 ± 3 Bars.
king circuit.(See corresponding operation).
- The control pressure should be obtained by progres-
- Carry out a road test.
sively increasing the pressure (without ever releasing
the pressure to adjust it).
E5-P01IC
328
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BRAKES
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types
Adjusting the load-sensitive brake compensator
- Untighten the screw (1).
- Move the spring rod.
- Decrease the length of the spring to increase the pressure.
- Increase the length of the spring to decrease the pressure.
- Tighten the screw (1) to 1,2 ± 0,25 m.daN.
- Check the brake pressure.
After the operation :
- Remove the checking tool [1].
- Bleed the braking circuit (See corresponding operation).
- Carry out a road test.
B3FP13VC
329
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BRAKES
XSARA PICASSO - All Types HANDBRAKE (Adjustment)
Adjustment :
Remove the handbrake trim (1).
Unclip the sound-deadening (2).
Raise and support the vehicle with the rear
wheels hanging free.
Check the correct routing of the brake cables under
the vehicle.
Apply and release the handbrake 4 times.
Set the handbrake to the 5th notch.
Tighten the nut (3) until the rear brakes are applied.
Pull the handbrake lever vigorously 4 to 5 times.
Set the handbrake to the 5th notch.
Check that the rear brakes are applied.
With the handbrake released, check that the wheels
can be turned freely by hand.
Lower the vehicle.
Refit the sound-deadening (2) and the handbrake
trim (1).
B3FP11YD
330
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BRAKES
BLEEDING THE BRAKES XSARA PICASSO - All Types
Tools Bleeding equipment of type «LURO» or similar.
IMPERATIVE : For bleeding the secondary circuit, use ELIT, LEXIA or PROXIA diagnostic tools.
Draining.
Drain the brake fluid reservoir as empty as possible using a syringe.
Disconnect the brake fluid warning lamp connector.
Retrieve the brake fluid reservoir from its supply pipes by pulling upwards.
Finish emptying the reservoir of brake fluid.
Clean the brake fluid reservoir.
Refit the brake fluid reservoir.
Reconnect the brake fluid warning lamp connector.
Filling
Refill the reservoir with brake fluid.
WARNING : Use only the recommended hydraulic fluids.
Bleeding.
NOTE : Two technicians are required.
IMPERATIVE: During bleed operations, ensure that the level of brake fluid is maintained
in the reservoir and top it up, use only new brake fluid.
Bleed each wheel cylinder, proceeding in the following order :
Rear right hand wheel.
Front left hand wheel.
Rear left hand wheel.
Front right hand wheel.
331
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ELECTRICAL
SYSTEM
SAXO STARTER MOTORS
Vehicles / models Manufacturer and Ref. Class Climat
VALEO D7E7
1.0i
1.1i BOSCH 1116003 1 H,T,C
1.4i (AIRCON) MELCO M002T13081
1.6i ( AIRCON)
VALEO D6 RA 571 3 VC
VALEO D7E7
SAXO
BOSCH 1116003 1 H,T
1.4i MELCO M002T13081
1.6i VALEO D7E5
2 C
BOSCH 1112041
VALEO D6 RA 571 3 VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
332
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STARTER MOTORS SAXO - XSARA
Vehicles / models Manufacturer and Ref. Class Climat
1.4i (Auto.)
1.6i (Auto./ 1.6i 16v VALEO D6 RA 571 3 H,T,C,VC
SAXO VALEO D7R11
ELECTRICAL
4 H,T,C
SYSTEM
1.5D BOSCH 1108162
VALEO D7R15 5 VC
VALEO D7E7
BOSCH 1116003 1 H,T
1.4i MELCO M002T13081
1.6i VALEO D7E5
2 C
BOSCH 1112041
XSARA
VALEO D6 RA 571 3 VC
VALEO D7E7
1.4i (Power-st. or aircon) BOSCH 1116003 1 H,T
1.6i (Power-st. or aircon) MELCO M002T13081
VALEO D6 RA 571 3 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
333
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XSARA STARTER MOTORS
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D7E5
1.4i (Power-st. + aircon) 2 H,T
1.6i (Power-st. + aircon) BOSCH 1112041
VALEO D6 RA 571 C,VC
ELECTRICAL
SYSTEM
1.6i (Auto.) VALEO D6 RA 571 H,T,C,VC
3
VALEO D6RA661
XSARA 1.8i H,T,C
BOSCH 1107019
1.8i 16v
BOSCH 1108085 4 VC
VALEO D6RA661
3 H,T
2.0i 16v BOSCH 1107019
BOSCH 1108085 4 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
334
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STARTER MOTORS XSARA
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D7R11
4 H,T,C
1.5D BOSCH 1108162
ELECTRICAL
VALEO D7R15 5 VC
SYSTEM
VALEO D6RA109
BOSCH 4 H,T
XSARA
1.9D MELCO M001T80381
VALEO D7R26 5 C
VALEO D7R27 6 VC
VALEO D7R26 5 H,T
2.0 HDi
VALEO D7R27 6 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
335
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BERLINGO STARTER MOTORS
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D7E7
BOSCH 1116003 1 H,T,C
1.1i
MELCO M002T13081
ELECTRICAL
SYSTEM
VALEO D6 RA 571 3 VC
VALEO D7E7
BOSCH 1116003 1 H,T
BERLINGO MELCO M002T13081
1.4i
VALEO D7E5
2 C
BOSCH 1112041
VALEO D6 RA 571 3 VC
VALEO D7E5
2 H,T
1.4i (Power-st. + aircon) BOSCH 1112041
VALEO D6 RA 571 3 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
336
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STARTER MOTORS BERLINGO
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D6RA661
3 H,T,C
1.8i BOSCH 1107019
BOSCH 1108085 4 VC
ELECTRICAL
SYSTEM
VALEO
BOSCH 4 H,T
MELCO
BERLINGO 1.9D
VALEO D7R26
5 C
MELCO
VALEO D7R27 6 VC
VALEO D7R26
5 H,T
2.0 HDi MELCO
VALEO D7R27 6 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
337
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XSARA PICASSO STARTER MOTORS
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D7E7
BOSCH 1116003 1 H,T
MELCO M002T13081
ELECTRICAL
1.6i
SYSTEM
VALEO D7E5
2 C
BOSCH 1112041
VALEO D6 RA 571 3 VC
XSARA PICASSO VALEO D7E5
2 H,T
1.6i (Power-st. + aircon) BOSCH 1112041
VALEO D6 RA 571 3 C,VC
VALEO D7E7
BOSCH 1116003 1 H,T
1.6i (Power-st. or aircon)
MELCO M002T13081
VALEO D6 RA 571 3 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
338
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STARTER MOTORS XSARA PICASSO
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D6RA661
3 H,T,C
1.8i 16v BOSCH 1107019
ELECTRICAL
XSARA PICASSO BOSCH 1108085 4 VC
SYSTEM
VALEO D7R26 5 H,T
2.0HDi
VALEO D7R27 6 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
339
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ALL TYPES STARTER MOTORS
Table of classes of starter motors
CLASS CLASS 2 CLASS 3 CLASS 4 CLASS 5 CLASS 6
Torque C 5.5 Nm 6 Nm 10 Nm 11.5 Nm 11.5 Nm
ELECTRICAL
Maximum power
SYSTEM
for a speed I ≤ 275 A I ≤ 300 A I ≤ 430 A I ≤ 470 A I ≤ 500 A
of 1200 rpm
340
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ALTERNATORS SAXO Without power-steering
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
1.0i/L3 VALEO A11 VI 55 H,T,C VALEO A11 VI 55 H,T,C
M 7 7
1.4i/L3 BOSCH A120310028 VC BOSCH A120310028 VC
ELECTRICAL
SYSTEM
VALEO A11 VI 55 8 VALEO A13 VI 96 H
7 H,T,C
1.1i/L3 M BOSCH A120310028 VALEO A11 VI 55
7 T,C
8 VALEO A13 VI 96 VC BOSCH A120310028
VALEO A11 VI 55 8 VALEO A13 VI 96 H,T,VC
7 H,T
1.4i/L3 A BOSCH A120310028 VALEO A11 VI 55
7 C
8 VALEO A13 VI 96 C,VC BOSCH A120310028
7 VALEO A11 VI 45 H,T,C 7 VALEO A11 VI 45 H,T,C
1.5D /L3 M
8 VALEO A13 VI 84 VC 8 VALEO A13 VI 84 VC
1.5D /L4 M 7 VALEO A11 VI 45 H,T,C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
341
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SAXO With power-steering ALTERNATORS
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
VALEO A11 VI 55 9 VALEO A13 VI 141+ H,T
7 H
BOSCH A120310028 8 VALEO A13 VI 96 C
ELECTRICAL
1.1i M
SYSTEM
8 VALEO A13 VI 96 T
9 VALEO A13 VI 141+ C,VC
VALEO A11 VI 55 9 VALEO A13 VI 141+ H
1.4i 7 H,T
1.6i M BOSCH A120310028 8 VALEO A13 VI 96 T,C
8 VALEO A13 VI 96 C,VC 9 VALEO A13 VI 141+ H,T,C,VC
8 VALEO A13 VI 96 H 9 VALEO A13 VI 141+ H,T,C,VC
1.4i A
9 VALEO A13 VI 141+ T,C,VC
7 VALEO A11 VI 45 H 8 VALEO A13 VI 84 T,C
1.5D M 8 VALEO A13 VI 84 T,C 9 VALEO A13 VI 142+ H,VC
9 VALEO A13 VI 142+ VC
8 VALEO A13 VI 96 H,T,C 9 VALEO A13 VI 141+ H,T
1.6i 16v M
8 VALEO A13 VI 96 C
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
342
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ALTERNATORS SAXO With power-steering
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
VALEO A11 VI 55 9 VALEO A13 VI 141+ H
7 H,T
1.1i M BOSCH A120310028 8 VALEO A13 VI 96 T,C,VC
ELECTRICAL
SYSTEM
8 VALEO A13 VI 96 C,VC
1.4i VALEO A11 VI 55 9 VALEO A13 VI 141+ H,T
7 H,T
1.6i M BOSCH A120310028 8 VALEO A13 VI 96 C,VC
1.6i 16v 8 VALEO A13 VI 96 C,VC
8 VALEO A13 VI 96 H 9 VALEO A13 VI 141+ H,T,C,VC
1.4i A
9 VALEO A13 VI 141+ T,C,VC
7 VALEO A11 VI 45 H 8 VALEO A13 VI 84 C
1.5D M
8 VALEO A13 VI 84 T,C 9 VALEO A13 VI 142+ H,T,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
343
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SAXO Police ALTERNATORS
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
SAXO POLICE
1.1i/1.4i M 9 VALEO A13 VI 141+ T
ELECTRICAL
SYSTEM
1.5D M 9 VALEO A13 VI 142+ T
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
344
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ALTERNATORS XSARA Without power-steering
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
VALEO A11 VI 55 H,T 8 VALEO A13 VI 96 H,C,VC
1.4i /L3 7
M BOSCH A120310028 C,VC VALEO A11 VI 55
ELECTRICAL
1.6i /L3 7 T
SYSTEM
8 VALEO A13 VI 96 C,VC BOSCH A120310028
1.5D M 8 VALEO A13 VI 84 T
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
345
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XSARA With power-steering ALTERNATORS
Classes and types
Engine Gbox. Without aircon. Climate With aircon. Climate
VALEO A11 VI 57 8 VALEO A13 VI 96 C,VC
7 H
1.4i /L3 M BOSCH A12220310104 VALEO A11 VI 57
ELECTRICAL
7 T
SYSTEM
8 VALEO A13 VI 96 T,C,VC BOSCH A12220310104
VALEO A11 VI 57 8 VALEO A13 VI 96 H,T,C,VC
7 H
1.6i /L3 M BOSCH A12220310104
8 VALEO A13 VI 96 T,C,VC
8 VALEO A13 VI 96 H VALEO A13 VI 101+ T,C,VC
9
1.6i /L4 M VALEO A13 VI 101+ MELCO A002TA2091 H
9 T,C,VC
MELCO A002TA2091
H VALEO A13 VI 101+ T,C,VC
9
1.6i A VALEO A13 VI 101+ MELCO A002TA2091 H
9 T,C,VC
MELCO A002TA2091
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
346
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ALTERNATORS XSARA With power-steering
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
7 BOSCH A120411525 C BOSCH A120411523 C,VC
BOSCH A120411523 8 MELCO A002TA1991
ELECTRICAL
H,T
SYSTEM
8 MELCO A002TA1991 T,C VALEO A13 VI 102
1.8i 16v /L3 M
VALEO A13 VI 102
VALEO A13 VI 101+ VC
9
MELCO A002TA2091
7 BOSCH A120411525 C BOSCH A120411523 C,VC
BOSCH A120411523 8 MELCO A002TA1991
H,T
1.8i /L3 8 MELCO A002TA1991 T VALEO A13 VI 102
M
2.0i 16 v /L3 VALEO A13 VI 102
VALEO A13 VI 101+
9 C,VC
MELCO A002TA2091
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
347
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XSARA With power-steering ALTERNATORS
Classes and types
Engine Gbox. Without aircon. Climate With aircon. Climate
BOSCH A120411523 12 VALEO A14 VI 14 H
8 MELCO A002TA1991 H VALEO A13 VI 101+
ELECTRICAL
9 T,C,VC
SYSTEM
2.0i 16v M VALEO A13 VI 102 MELCO A002TA2091
VALEO A13 VI 101+ T
MELCO A002TA2091 C,VC
9
1.5D (poulie 59.4) VALEO A13 VI 273+ T 9 VALEO A13 VI 273+ T
M
1.5D (poulie 66.6) VALEO A13 VI 142+ T 9 VALEO A13 VI 142+ T
VALEO A13 VI 203 H,T VALEO A13 VI 203 H
8 MELCO A002TB2191 8 MELCO A002TB2191
1.9D /L3 M C,VC C,VC
MELCO A002TB4791 MELCO A002TB4791
7 VALEO A11 VI 91 T
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
348
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ALTERNATORS XSARA With power-steering
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
VALEO A13 VI 94+ VALEO A14 VI 13
9 H 12 H
MELCO A002TA2094 MELCO A002TA5591
ELECTRICAL
SYSTEM
BOSCH A120411513 VALEO A13 VI 94+
9 T
1.9TD M 8 VALEO A13 VI 95 T,C,VC MELCO A002TA2094
MELCO A002TA1994 BOSCH A120411513
8 VALEO A13 VI 95 C,VC
MELCO A002TA1994
7 VALEO A11 VI 91 H VALEO A13 VI 204+
9 MELCO A002TB2291 H
MELCO A002TB4891
2.0 HDi M
VALEO A14 VI 27+ VALEO A14 VI 27+
15 BOSCH A1222051611 T,C,VC 15 BOSCH A1222051611 T,C,VC
MELCO A004TF0091 MELCO A004TF0091
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
349
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XSARA With power-steering - XSARA Police ALTERNATORS
Classes and types
Engine Gbox. Without aircon. Climate With aircon. Climate
VALEO A13 VI 203 VALEO A13 VI 204+
8 MELCO A002TB2191 H 9 MELCO A002TB2291 H
ELECTRICAL
SYSTEM
MELCO A002TB4791 MELCO A002TB4891
2.0 Hdi A
VALEO A14 VI 27+ VALEO A14 VI 27+
15 BOSCH A1222051611 T,C,VC 15 BOSCH A1222051611 T,C,VC
MELCO A004TF0091 MELCO A004TF0091
XASARA POLICE
1.4i VALEO A13 VI 141+ H,T,C,VC 9 VALEO A13 VI 141+ H,T,C,VC
M 9 VALEO A13 VI 94+ H,T VALEO A14 VI 13 H,T
1.9D 12
MELCO A002TA2094 C,VC MELCO A002TA5591 C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
350
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ALTERNATORS XSARA PICASSO
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
VALEO A11 VI 91 H,T VALEO A13 VI 204+
7 9 H
BOSCH A120316004 C,VC MELCO A002TB4891
ELECTRICAL
1.6i M
SYSTEM
MELCO A002TB4791 T,C,
8
VALEO A13 VI 203 VC
MELCO A002TB4791 T VALEO A13 VI 204+
8 9 H,T
VALEO A13 VI 203 C,VC MELCO A002TB4891
1.8i 16v M
VALEO A11 VI 91 MELCO A002TB4791
7 H 8 C,VC
BOSCH A120316004 VALEO A13 VI 203
VALEO A13 VI 27+ VALEO A13 VI 27+
15 15
BOSCH A120516111 T,C,VC BOSCH A120516111 T,C,VC
(*) (*)
MELCO A004TF0091 MELCO A004TF0091
2.0 Hdi M
VALEO A13 VI 204+ H,T 12 MELCO A003TA0891 H
9 VALEO A13 VI 204+
MELCO A002TB4891 C,VC 9 T,C,VC
MELCO A002TB4891
(*) = With cabin heating
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
351
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BERLINGO Without power-steering ALTERNATORS
Classes and types
Engine Gbox. Without aircon. Climate With aircon. Climate
1.1i /L3 8 VALEO A13 VI 96 T
VALEO A11 VI 55 VALEO A11 VI 55
ELECTRICAL
1.4i /K H H
BOSCH A120310028 BOSCH A120310028
SYSTEM
7 7
VALEO A11 VI 55 VALEO A11 VI 55
1.4i /L3 H,T,C H,T,C
BOSCH A120310028 BOSCH A120310028
VALEO A13 VI 203 H VALEO A13 VI 203
1.9D L3/W3 8 8 VC
MELCO A002TB2191 C,VC MELCO A002TB2191
M
7 VALEO A11 VI 91 H 7 VALEO A11 VI 91 T
1.9D L4/W4 VALEO A13 VI 203 VALEO A13 VI 203
T,C,VC 8 H,C,VC
MELCO A002TB2191 MELCO A002TB2191
8
VALEO A13 VI 203 VALEO A13 VI 204+
H 9 H
MELCO A002TB2191 MELCO A002TB2291
2.0 HDi VALEO A14 VI 27+ VALEO A14 VI 27+
15 MELCO A004TF0091 T,C,VC 15 MELCO A004TF0091 T,C,VC
BOSCH A122051611 BOSCH A122051611
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
352
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ALTERNATORS BERLINGO With power-steering
Classes and types
Engine Gbox.
Without aircon. Climate With aircon. Climate
VALEO A11 VI 55
7 H
BOSCH A120310028
ELECTRICAL
1.1i /L3 M
SYSTEM
8 VALEO A13 VI 96 T
9 VALEO A13 VI 141+ C,VC
8 VALEO A13 VI 96 C VALEO A11 VI 55
7 H,T,C
1.4i /L3 M VALEO A11 VI 55 BOSCH A120310028
7 H,T
BOSCH A120310028
8 BOSCH A120411523 BOSCH A120411523 H,T
MELCO A002TA1991 T,C 8 MELCO A002TA1991
C,VC
VALEO A13 VI 102 VALEO A13 VI 102
1.8i M
9 VALEO A13 VI 101+
VC
MELCO A002TA2091
7 BOSCH A120411525 H
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
353
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BERLINGO With power-steering ALTERNATORS
Classes and types
Engine Gbox. Without aircon. Climate With aircon. Climate
VALEO A13 VI 203 H VALEO A13 VI 203
8 8
MELCO A002TB2191 MELCO A002TB2191
ELECTRICAL
1.9D /L3 H,T,C
SYSTEM
VALEO A13 VI 204+ T,C VALEO A13 VI 204+
9 9
MELCO A002TB2291 MELCO A002TB2291
7 VALEO A11 VI 91 H 7 VALEO A11 VI 91 T
1.9D /L4 VALEO A13 VI 203 VALEO A13 VI 203
M T,C,VC 8 H,C,VC
MELCO A002TB2191 MELCO A002TB2191
8
VALEO A13 VI 203 VALEO A13 VI 204+
H 9 H
MELCO A002TB2191 MELCO A002TB2291
2.0 HDi VALEO A14 VI 27+ VALEO A14 VI 27+
15 MELCO A004TF0091 T,C,VC 15 MELCO A004TF0091 T,C,VC
BOSCH A122051611 BOSCH A122051611
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
354
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CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR ALL TYPES
CHECKING THE ALTERNATOR OUTPUT Output under 13.5 V
Intensity (A) / Alternator speed
Connect as shown in the diagram opposite, using an ammeter (A), a
voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Speed
2000 3000 4000
ELECTRICAL
Adjust the engine speed (table opposite) and rheostat charge tr/min tr/min tr/min
SYSTEM
according to the vehicle's equipment specification in order to obtain Class
U = 13.5 V.
5 29 A 39 A 43 A
Reminder : The excitation energising current will flow through the
warning lamp - check that the warning lamp comes on when the
ignition is switched on. It must go out when the engine has started 7 42 A 54 A 59 A
(accelerate slightly).
8 49 A 62 A 68 A
CHECKING THE VOLTAGE REGULATOR
9 62 A 76 A 83 A
the rheostat to zero and disconnect all the electrical consumers.
Display 5000 alternator rpm. If U alternator is > 14.7 V, the regulator is
faulty.Set
12 72 A 90 A 100 A
Note : These tests should be performed with the engine hot and the
battery fully charged. 15 99 A 128 A 140 A
D1AP01SC
355
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SAXO - XSARA - XSARA PICASSO PRE-HEATING AND STARTING SYSTEMS
Pre / Post heating
Vehicles / models Pre-heater plugs Pre-heater control unit
(pre-heating duration at 20°C)
BERU 0 100 226 188 LUCAS R0490001B
ELECTRICAL
SAXO 10s / 150s
SYSTEM
CHAMPION CH 168 BOSCH A 281 023 045
1.5D
BERU 0 100 226 188 LUCAS R0490001B
10s / 150s
CHAMPION CH 168 BOSCH A 281 023 045
BERU 0 100 226 186 BOSCH 0 281 003 005
1.9TD 6s / 180s
BOSCH 0 250 201 039 VALEO 73507212
XSARA
CHAMPION CH185 LUCAS R0490001B
1.9D 10s / 150s
BERU 0 100 226 371 BOSCH A 281 023 045
CHAMPION CH170 NAGARES 735068 Controlled by the diesel injection
2.0 Hdi
BOSCH 0250202032 CARTIER 960411-P ECU.
356
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PRE-HEATING AND STARTING SYSTEMS BERLINGO
Pre / Post heating
Vehicles / models Pre-heater plugs Pre-heater control unit
(pre-heating duration at 20°C)
CHAMPION CH185 LUCAS R0490001B
ELECTRICAL
1.9D 10s / 150s
SYSTEM
BERU 0 100 226 371 BOSCH A 281 023 045
BERLINGO
CHAMPION CH170 NAGARES 735068 Controlled by the diesel injection
2.0 HDi
BOSCH 0250202032 CARTIER 960411-P ECU.
357
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ALL TYPES AIR CONDITIONING R 134 a (HFC)
Compressor
Refrigerant
Vehicle Engine Date Variable Oil quantity Oil
refill
Capacity cc reference
CONDITIONING
TU - TUD-TT 850 gr +0 - 50 gr
AIR
SAXO TU TT MY 2000 # 825 gr ± 25 gr SD 6 V 12
TUD TT 795 gr ± 25 gr
TU XU (1) 975 gr ± 25 gr SD 7 V 12 135 SP 10
09/97 #
XSARA XUD - DW (1) 875 gr ± 25 gr) SD 7 V 16
# 09/2000
TU-XU (2) 725 gr ± 25 gr SD 7 V 12
MY 2000 #
XUD - DW (3) 700 gr ± 25 gr SD 7 V 16
(1) = With VALEO air conditioning, XSARA loop.
(2) = With BEHR RF air conditioning and TGK 2.0/2.5 pressure valve, 306 loop.
(3) = With VALEO air conditioning, 306 loop.
358
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AIR CONDITIONING R 134 a (HFC) ALL TYPES
Compressor
Refrigerant
Vehicle Engine Date Variable Oil quantity Oil
refill
Capacity cc reference
TU-TT SD 6 V 12
SD 6 V 12
EW (1)
570 gr +0 -50 gr
DW (1) SD
SD 7
7VV 16
16
XSARA 590 gr +0 -50 gr
Gbox. 09/2000 # SD 6 V 12
09/2000 # EW (2) and (3)
Auto. 500 gr +0 -50 gr
CONDITIONING
Gbox. 590 gr +0 -50 gr 135 SP 10
DW (2) and (3)
Auto. 500 gr +0 -50 gr SD 7 V 16
AIR
XU 10 725 gr +0 -50 gr
TU SD 6 V 12
XSARA 12/1999 # 675 gr ± 50 gr
EW7-DW10
PICASSO SD 7 V 16
BRASIL All Types 03/2001 # 800 gr ± 25 gr
(1) = Circuit with damper capacity.
(4) RFTD = With automatic air conditioning.
(5) RF = With manual air conditioning.
359
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ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Click-fit connector removing/fitting tool
Vehicle Ø Inch Ring colour Tool kit 4164-T
SAXO
TT
XSARA 5/8 Black 8005-T.A.
XSARA BP
C5HP073C
PICASSO HP 3/8 Red 8005-T.C
Tightening torques (m.daN).
Unions
CONDITIONING
Ø Pipes Steel/Steel Aluminium/Steel
AIR
M 06 1.7 ± 0.3 1.3 ± 0.3
M 08 3.8 ± 0.3 2 ± 0.2
M 10 4 ± 0.3 2.5 ± 0.3
NOTE : Tighten the union to the recommended torque using a retaining spanner whenever possible.
NOTE : For operations concerning draining, drying (empty), checking and recharging of a system: refer to BRE 0290.
WARNING : For R 134.a quantities (See table on page: 358).
360
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SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES
Presence of pollen filter
Vehicle Equipment RPO No. Presence of filter Observations
AX-SAXO-ZX-BX-C15 All Types NO
Without aircon YES (Behr) Exc. driving school
XSARA
XSARA PICASSO Base aircon YES (Larger)
Regulated aircon YES (Valeo)
Without aircon NO
XANTIA I and II
Regulated aircon YES Except Brazil
XM I and II All Types NO
Without aircon NO
CONDITIONING
Base aircon NO
EVASION # 8148 Do not fit Ingress of water
AIR
8148 # 8421 YES (Behr) Body modification
Automatic aircon YES if Exclusive 2 blowers
8421 #
NO if X and SX 1 blower
BERLINGO Without aircon NO (Valeo)
Base aircon YES (Vaeo)
DISPATCH All Types NO
Base aircon NO
Without aircon NO
RELAY
Base or double aircon YES
361
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XSARA - All Types SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
BEHR plate evaporator Pollen filter
CONDITIONING
C5HP07JC C5FP075D
Remove-refit.
Remove :
AIR
- The interior trim (1).
- The cover (4).
- The pollen filter (3).
Concerns vehicles equipped with aircon without temperature regulation.
Fitting of a new pollen filter necessistates the following operations :
- Engage the pollen filter upwards (following arrow "c").
- Slide the pollen filter towards the rear (following arrow "d").
- Position the index (4) on the cover forward of the pollen filter.
C5HP062C ((4) Index on the cover).
362
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SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA - All Types
BEHR condenser with integral reservoir (16 Ti)
Petrol engine
The condenser is equpped with a cylinder (1) that acts as the fluid reser-
voir which in turn incorporates a filter cartridge.
NOTE : As soon as the air conditioning loop has been open for more than
5 minutes, the filter/dryer cartridge assembly should be replaced (no set
interval).
C5HP07BC
CONDITIONING
Instruction for replacing the filter/dryer cartridge.
Engine Diesel
AIR
- After undoing the cap (TORX 70), the cold loop must be depressurised.
- Unscrew the cap and clean the cap's thread.
- Take out the filter/dryer cartridge.
- Clean the threaded zone of the condenser reservoir
- Fit the new filter/dryer cartridge.
- Lubricate the cap's O-ring seals with compresser oil. (New seals).
- Screw the cap back on, tighten to 1.4 ± 0.2 m.daN.
C5HP060C
363
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XSARA PICASSO SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
BEHR plate evaporator Pollen filter
CONDITIONING
AIR
Remove:
- The three screws (1).
- The cover (2).
C5HP062C B1BP23ED
- Remove the pollen filter.
364
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SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO
BEHR condenser with integral reservoir (16 Ti)
The condenser is equpped with a cylinder (1) that acts as the fluid reservoir which
in turn incorporates a filter cartridge.
NOTE : As soon as the air conditioning loop has been open for more than 5 minutes,
the filter/dryer cartridge assembly should be replaced (no set interval).
Instruction for replacing the filter/dryer cartridge.
- After undoing the cap (TORX 70), the cold loop must be depressurised.
- Unscrew the cap and clean the cap's thread.
CONDITIONING
- Take out the filter/dryer cartridge.
- Clean the threaded zone of the condenser reservoir.
AIR
- Fit the new filter/dryer cartridge.
- Lubricate the cap's O-ring seals with compresser oil.(New seals).
- Screw the cap back on, tighten to 1.4 ± 0.2 m.daN.
C5HP07BC
365
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ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Compressor lubricant.
ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.
Checking the compressor oil level.
There are three specific cases :
1) Repairs to a system without leaks.
2) Slow leak.
3) Fast leak.
1) Repairing a system without leaks.
CONDITIONING
a) Using draining/recovery equipment not fitted with an oil decanter.
- Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil.
AIR
- No more oil should be added when filling the system with R 134.a fluid.
b) Using draining/filling equipment fitted with an oil decanter.
- Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook.
- Measure the amount of oil recovered.
- Add the same amount of NEW oil when filling the system with R 134.a fluid.
c) Replacing a compressor.
- Remove the old compressor, drain it and measure the oil quantity.
- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.
- No more oil should be added when filling the system with R 134.a fluid.
366
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SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES
Checking the compressor oil level (continued)
2) Slow leak.
- Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all.
3) Fast leak.
- This type of leak causes both oil loss as well as allowing air to enter the system.
CONDITIONING
It is therefore necessary to
AIR
- Replace the dehydrator.
- Drain as much oil as possible (when replacing the faulty component).
Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.
367
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ALL TYPES CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING TEMPERATURES
TOOLS Checks
Two thermometers If all these conditions are met, take the following action :
- Start the engine, with the air conditioning off, and wait for the cooling fan
Preliminary conditions. first speed to cut in.
- Operate the air conditioning and set the engine speed to 2500 rpm.
Position of the air conditioning controls :
- Maximum cold air. NOTE : If the ambient temperature reaches 40 °C, the engine speed will
CONDITIONING
- Air blower in maximum position. return to 2000 rpm in order to prevent the compressor from being cut off
- Air distributor in "ventilation" position, with the dashboard vents open. by the High Pressure safety device (Pressostat).
- Air intake flap in "exterior air" position.
AIR
After the air conditioning has been on for three minutes, measure :
- the ambient temperature in the workshop,
Conditions and vehicle equipment. - the temperature of the air coming from the central vents.
- Boot closed.- Compare the two values using the table overleaf.
Doors and windows shut.
- Ensure the vehicle is in a sheltered area (away from wind, sun, etc..).
368
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES
CHECKING TEMPERATURES (continued)
Vehicle using R134.a fluid (Compressor with variable capacity)
Ambient temperature in °C 40 35 30 25 20 15
Vehicles
SAXO 17 ± 3 13 ± 3 11 ± 3 9±3 8±3
Air temperature
CONDITIONING
from the central
ventsin °C XSARA 21 ± 3 17 ± 3 15 ± 3 12 ± 3 10 ± 3
AIR
XSARA 22 ± 3 16 ± 3 12.5 ± 3 10 ± 3 8±3 6.5 ± 3
PICASSO
NOTE : In general, the temperature of the air being blown from the central vents should be around 5°C to 8°C.
369
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ALL TYPES CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING PRESSURES
TOOLS - 1 Charging station. CHECK
- 2 Thermometers. - The temperature of the air coming from the central vents (see table)
Once the preliminary conditions, vehicle equipment and checks have - The High Pressure.
been fulfilled (see table) : After the air conditioning has been on for three - The Low Pressure.
minutes, record the following parameters : Compare the values recorded with the table below, or the graphs.
Vehicle using R134.a fluid (Compressor with variable capacity)
Ambient temperature in °C 40 35 30 25 20 15
Vehicles Engines
High pressure (Bars) 20 ± 3 18 ± 3 16 ± 3 13 ± 3 11 ± 3 9±3
SAXO All Types
Low pressure (Bars) 3 ± 0.3
CONDITIONING
High pressure (Bars) 22 ± 3 20 ± 3 17 ± 3 16 ± 3 15 ± 3 11 ± 3
TU-TUD
Low pressure (Bars) 3 ± 0.3 2.4 ± 0.3 2 ± 0.3
AIR
High pressure (Bars) 27 ± 3 24 ± 3 22 ± 3 18 ± 3 17 ± 3 14 ± 3
XSARA XU
Low pressure (Bars) 3 ± 0.3 2 ± 0.3
High pressure (Bars) 23 ± 3 16 ± 3 14 ± 3
XUD
Low pressure (Bars) 3 ± 0.3 2 ± 0.3
High pressure (Bars) TU 25.5 ± 3 20.5 ± 3 18 ± 3 20 ± 3 13.5 ± 3 11 ± 3
Low pressure (Bars) XSARA EW 4 ± 0.3 3.5 ± 0.3 3 ± 0.3
High pressure (Bars) PICASSO 25 ± 3 22.5 ± 3 20 ± 3 17 ± 3 15 ± 3
Low pressure (Bars) DW
4 ± 0.3 3.5 ± 0.3 3 ± 0.3
370
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES
CHECKING PRESSURES (continued)
Low pressure Low pressure Low pressure
too low normal too high
- Insufficient fluid charge. - Faulty pressure control valve.
High pressure - Cooling fan speed unsuitable.
- Constriction of the HP system. - Faulty compressor.
too low - Faulty compressor.
- Dirty pressure control valve.
High pressure - Faulty compressor. - Circuit normal - Cooling fan speed unsuitable.
normal - Dirty evaporator.
CONDITIONING
- Excessive fluid charge.
- Faulty pressure control valve.
AIR
High pressure - Presence of solid matter in the system. - Dirty condenser.
too high - System blocked. - Dirty condenser. - Faulty pressure control valve.
- Water in the system.
- Cooling fan speed unsuitable.
Checking the pressure at temperatures between 15°C and 35°C for information only.
In general, the pressure should be approximately :
- for R134.a fluid, less than 2 Bars (Low pressure), and between 13 and 24 Bars (High pressure).
371
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SAXO # 09/1999 AIR CONDITIONING SYSTEM R 134.a
# 09/1999 (3) Click-fit union.
CONDITIONING
C5HP12EC
AIR
Tightening torques (m.daN).
a- 1 (1) Click-fit union..
b- 3 (2) Low pressure valve.
c- 2
d - 1.3 (3)Pressostat
e - 1.3 (4) High pressure valve.
NOTE : (b) = flange coupling.
C5HP12DD
372
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AIR CONDITIONING SYSTEM R 134.a SAXO # 09/1999
# 09/1999 (3) Click-fit union.
CONDITIONING
C5HP12EC
Tightening torques (m.daN).
AIR
(1) High pressure valve
(2) Low pressure valve.
(3) Click-fit union
(4) Pressostat (1 seal Ø 10,82)
(5) Dryer (2 seals Ø 7,65)
(6) Relief valve, tighten to 0,43 m.daN ± 0,1
(1 seal Ø 7,65 - 1seal Ø 16,5)
(7) Compressor fixing flange 3 ± 0,8 m.daN (2 seals Ø 20)
(8) (O-ring seal Ø 7,65)
C5HP15UP
373
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SAXO 09/1999 # AIR CONDITIONING SYSTEM R 134.a
09/1999 # Click-fit union.
CONDITIONING
C5HP12EC
Tightening torques m.daN.
AIR
(1) High pressure valve
(2) Low pressure valve
(3) Click-fit union.
(4) Pressostat (1 Joint Ø 10.82)
(5) Dryer (2 Joints Ø 7.65)
(6) Détendeur serrage 0.43 m.daN ± 0.1
(1 Joint Ø 7.65-1Joint Ø 16.5)
(7) Compressor fixation bride 3 ± 0.8 m.daN (2 Joints Ø 20)
(8) (Joint torique Ø 7.65)
C5HP15AP
374
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AIR CONDITIONING SYSTEM R 134.a SAXO - All Types
Checking the air conditioning system
Key
T/P = Scale of:
- Temperature (°C), average of air from the central vents.
- Pressure, High (Bars).
- Pressure, Low (Bars).
CONDITIONING
Te = Exterior temperature (°C).
AIR
HP = Pressure at compressor outlet (Bars).
Ta = Temperature (°C) of air blown from the vents.
BP = Pressure at compressor inlet (Bars).
C5HP067D
375
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XSARA TU # 09/2000 AIR CONDITIONING SYSTEM R 134.a
(1) - High pressure valve
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
Tightening torques m.daN.
CONDITIONING
(a) 0.8
(b) 4 ± 0.4
AIR
(c) 0.8
A Right hand drive.
C5HP15VP
376
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AIR CONDITIONING SYSTEM R 134.a XSARA TUD # 09/2000
(5) Click-fit union.
CONDITIONING
C5HP12EC
(1) - High pressure valve
AIR
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
(5) - Click-fit union
Tightening torques m.daN.
(a) 0.8
(b) 4 ± 0.4
(c) 0.8
C5HP15YP
377
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XSARA TU - TUD # 09/2000 AIR CONDITIONING SYSTEM R 134.a
Checking the air conditioning system
Key
T/P = Scale of:
- Temperature (°C), average of air from the central vents.
- Pressure, High (Bars).
- Pressure, Low (Bars).
CONDITIONING
Te = Exterior temperature (°C).
AIR
HP = Pressure at compressor outlet (Bars).
T CX = Temperature (°C) of air blown from the vents.
BP = Pressure at compressor inlet (Bars).
C5HP076D
378
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AIR CONDITIONING SYSTEM R 134.a XSARA XU # 09/2000
(1) - High pressure valve
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
Tightening torques m.daN.
CONDITIONING
(a) 0.8
(b) 4 ± 0.4
AIR
(c) 0.8
A Right hand drive.
C5HP15WP
379
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XSARA XU # 09/2000 AIR CONDITIONING SYSTEM R 134.a
Checking the air conditioning system
Key
T = Temperature (C°) and High Pressure (Bars).
P = Low pressure (Bars).
Te = Exterior temperature (C°).
CONDITIONING
HP = Pressure at compressor outlet (Bars).
AIR
T Cx = Temperature of air blown from the central air vents (C°).
BP = Pressure at compressor inlet (Bars).
C5HP077D
380
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AIR CONDITIONING SYSTEM R 134.a XSARA XUD # 09/2000
(1) - High pressure valve
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
Tightening torques m.daN.
CONDITIONING
(a) 0.8
(b) 4 ± 0.4
AIR
(c) 0.8
A Right hand drive.
C5HP15XP
381
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XSARA XUD # 09/2000 AIR CONDITIONING SYSTEM R 134.a
Checking the air conditioning system
Key
T/P = Scale of:
- Temperature (°C), average of air from the central vents.
- Pressure, High (Bars).
- Pressure, Low (Bars).
CONDITIONING
Te = Exterior temperature (°C).
AIR
HP = Pressure at compressor outlet (Bars).
T CX = Temperature (°C) of air blown from the vents.
BP = Pressure at compressor inlet (Bars).
C5HP078D
382
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AIR CONDITIONING SYSTEM R 134.a XSARA TU 09/2000 #
(1) - High pressure valve
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
Tightening torques m.daN.
CONDITIONING
(a) 0.8
(b) 4 ± 0.4
AIR
(c) 0.8
A Right hand drive.
C5HP16RP
383
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XSARA EW 09/2000 # AIR CONDITIONING SYSTEM R 134.a
(1) - High pressure valve
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
Tightening torques m.daN.
CONDITIONING
(a) 0.8
(b) 4 ± 0.4
AIR
(c) 0.8
A Right hand drive.
C5HP16SP
384
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AIR CONDITIONING SYSTEM R 134.a XSARA DW 09/2000 #
(1) - High pressure valve
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
Tightening torques m.daN.
(a) 0.8
CONDITIONING
(b) 4 ± 0.4
(c) 0.8
AIR
A Right hand drive.
C5HP16VP
385
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XSARA XU10J4RS 09/2000 # AIR CONDITIONING SYSTEM R 134.a
(1) - High pressure valve
(2) - Low pressure valve
(3) - Pressostat
(4) - Dryer
Tightening torques m.daN.
(a) 0.8
CONDITIONING
(b) 4 ± 0.4
(c) 0.8
AIR
A Right hand drive.
C5HP16TP
386
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AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU
(1) High pressure valve .
(2) Low pressure valve.
(3) High pressure click-fit union (tool 8005-T.C).
(4) Low pressure click-fit union (tool 8005-T.A).
(5) Pressostat. 1.8 ± 0.6 m.daN
(6) Filter/dryer cartridge cap.
CONDITIONING
Tightening torques m.daN.
AIR
- a 0.8.± 0.1
- b 0.5.± 0.1
- c 1.4 ± 0.2.
- d 2.5 ± 0.25.
C5HP13PP
387
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XSARA PICASSO EW7 AIR CONDITIONING SYSTEM R 134.a
(1) High pressure valve .
(2) Low pressure valve.
(3) High pressure click-fit union (tool 8005-T.C).
(4) Low pressure click-fit union (tool 8005-T.A).
(5) Pressostat. 1.8 ± 0.6 m.daN
(6) Filter/dryer cartridge cap.
CONDITIONING
Tightening torques m.daN.
AIR
-a 0.8.± 0.1
-b 0.5.± 0.1
-c 1.4 ± 0.2.
HP BP compressor fixing flange 2.5 ± 0.25.
C5HP13QP
388
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AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU - EW7
Checking the air conditioning system
Key
T/P = Scale of:
- Temperature (°C), average of air from the central vents.
- Pressure, High (Bars).
- Pressure, Low (Bars).
CONDITIONING
Te = Exterior temperature (°C).
AIR
HP = Pressure at compressor outlet (Bars).
Ta = Temperature (°C) of air blown from the vents.
BP = Pressure at compressor inlet (Bars).
C5HP150D
389
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XSARA PICASSO DW10 AIR CONDITIONING SYSTEM R 134.a
(1) High pressure valve .
(2) Low pressure valve.
(3) High pressure click-fit union (tool 8005-T.C).
(4) Low pressure click-fit union (tool 8005-T.A).
(5) Pressostat. 1.8 ± 0.6 m.daN
(6) Filter/dryer cartridge cap
CONDITIONING
Tightening torques m.daN.
AIR
-a 0.8.± 0.1
-b 0.5.± 0.1
-c 1.4 ± 0.2.
HP BP compressor fixing flange 2.5 ± 0.25.
C5HP13RP
390
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AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO DW10
Checking the air conditioning system
Key
T/P = Scale of:
- Temperature (°C ), average of air from the central vents.
- Pressure, High (Bars).
- Pressure, Low (Bars).
CONDITIONING
Te = Exterior temperature (°C).
AIR
HP = Pressure at compressor outlet (Bars).
Ta = Temperature (°C) of air blown from the vents.
BP = Pressure at compressor inlet (Bars).
C5HP14ZD
391
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